Support Assembly For Photovoltaic Modules And Mounting System Using The Same

ABSTRACT

A support assembly for mounting photovoltaic modules on a support surface and a mounting system including the same are disclosed herein. The support assembly may comprise a the body portion including a base portion and at least one upright support member coupled to the base portion, the at least one upright support member comprising an integrally formed ballast tray slot in one side thereof for receiving an upturned edge of a ballast tray; and at least one clamp subassembly coupled to the at least one upright support member of the body portion, the at least one clamp subassembly configured to be coupled to one or more photovoltaic modules. In addition to a plurality of support assemblies, the mounting system may further comprise at least one ballast tray support bracket, the ballast tray support bracket supporting a portion of a ballast tray on the support surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is a continuation-in-part of U.S. applicationSer. No. 16/035,630, filed on Jul. 14, 2018; which claims priority toU.S. Provisional Application No. 62/532,958, filed on Jul. 14, 2017; andis a continuation-in-part of U.S. application Ser. No. 15/218,491, filedon Jul. 25, 2016, now U.S. Pat. No. 10,033,328; which is acontinuation-in-part of U.S. application Ser. No. 14/948,342, filed onNov. 22, 2015, now U.S. Pat. No. 9,413,285; which is a continuation ofU.S. application Ser. No. 14/521,951, filed on Oct. 23, 2014, now U.S.Pat. No. 9,196,755; which is a continuation-in-part of U.S. applicationSer. No. 13/923,303, filed on Jun. 20, 2013, now U.S. Pat. No.8,869,471; which claims the benefit of U.S. provisional application No.61/690,974, filed Jul. 10, 2012; and is a continuation-in-part of U.S.application Ser. No. 13/273,525, filed Oct. 14, 2011, now U.S. Pat. No.8,635,818; which claims the benefit of U.S. provisional application No.61/447,883, filed Mar. 1, 2011, all of the disclosures of which areherein expressly incorporated by reference in their entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable.

REFERENCE TO APPENDIX

Not Applicable.

FIELD OF THE INVENTION

The field of the present invention generally relates to mounting systemsand methods and, more particularly, to systems and methods for mountingphotovoltaic modules or panels on support surfaces such as, for example,building rooftops, the ground, or the like.

BACKGROUND

A photovoltaic (PV) panel, often referred to as a solar panel or PVmodule, is a packaged interconnected assembly of solar cells also knownas PV cells. The PV module is typically used as a component of a largerPV system to generate and supply electricity in commercial andresidential applications. Because a single PV module can only produce alimited amount of power, most installations contain several PV modulesto form a PV array. The PV array is often mounted on a building rooftopor the ground with each of the PV modules in a fixed position facinggenerally south.

There are many mounting systems for securing PV modules to rooftops thatadequately withstand wind loads. However, these prior mounting systemsare not environmentally friendly, are relatively expensive to produce,time consuming to install, custom fabricated to each type or brand of PVmodule, and/or can damage the rooftop by penetrating a roof membrane.Also, these prior mounting systems occupy an excessive amount of roofspace, thereby decreasing the power density of the photovoltaic array.In addition, these prior mounting systems do not offer any row-to-rowgrounding capabilities. Accordingly, there is a need in the art forimproved mounting systems for PV modules in rooftop applications.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

Accordingly, the present invention is directed to a support assembly forphotovoltaic modules and a mounting system using the same thatsubstantially obviates one or more problems resulting from thelimitations and deficiencies of the related art.

In accordance with one or more embodiments of the present invention,there is provided a support assembly for supporting one or morephotovoltaic modules on a support surface. The support assembly includesa body portion, the body portion including a base portion and at leastone upright support member coupled to the base portion, the at least oneupright support member comprising an integrally formed ballast tray slotin one side thereof for receiving an upturned edge of a ballast tray;and at least one clamp subassembly, the at least one clamp subassemblycoupled to the at least one upright support member of the body portion,the at least one clamp subassembly configured to be coupled to one ormore photovoltaic modules.

In a further embodiment of the present invention, the base portioncomprises at least one wire clip slot for receiving a portion of a wireclip that accommodates one or more wires of the one or more photovoltaicmodules.

In yet a further embodiment, the base portion comprises at least oneweep hole for draining water from a recessed portion of the baseportion.

In still a further embodiment, the base portion comprises at least oneintegrally formed foot member disposed on an underside of the baseportion, the at least one integrally formed foot member configured to bedisposed on the support surface.

In yet a further embodiment, the at least one upright support member ofthe base portion comprises a pair of spaced-apart upright supportmembers coupled to the base portion, each of the upright support membersincluding a respective ballast tray slot integrally formed in one sidethereof for receiving a respective upturned edge of the ballast tray.

In accordance with one or more other embodiments of the presentinvention, there is provided a mounting system for supporting aplurality of photovoltaic modules on a support surface. The mountingsystem includes a plurality of photovoltaic modules disposed in anarray, the array including a plurality of rows of photovoltaic modules;and a plurality of separate and spaced-apart support assembliessupporting and orienting the photovoltaic modules in the array on thesupport surface. Each of the spaced-apart support assemblies includes abody portion, the body portion including a base portion and at least oneupright support member coupled to the base portion, the at least oneupright support member comprising an integrally formed ballast tray slotin one side thereof; and at least one clamp subassembly, the at leastone clamp subassembly coupled to the at least one upright support memberof the body portion, the at least one clamp subassembly configured to becoupled to one or more of the photovoltaic modules. The mounting systemfurther includes a ballast tray coupled to one or more of the supportassemblies, the ballast tray configured to receive one or more ballaststherein, the ballast tray comprising at least one upturned edge, the atleast one upturned edge of the ballast tray received within the ballasttray slot of the at least one upright support member of the supportassembly.

In a further embodiment of the present invention, the at least oneupright support member of at least one of the support assembliescomprises a pair of spaced-apart upright support members coupled to thebase portion, each of the upright support members including a respectiveballast tray slot integrally formed in one side thereof; and the atleast one upturned edge of the ballast tray comprises a first upturnededge and a second upturned edge, the first upturned edge beingoppositely disposed relative to the second upturned edge, and the firstand second upturned edges of the ballast tray being received withinrespective ones of the ballast tray slots of the pair of spaced-apartupright support members.

In yet a further embodiment, the ballast tray comprises at least onedrainage hole for draining water from the ballast tray.

In still a further embodiment, the mounting system further comprises atleast one ballast tray support bracket, the at least one ballast traysupport bracket supporting a portion of the ballast tray on the supportsurface.

In yet a further embodiment, the at least one ballast tray supportbracket comprises a photovoltaic module frame slot formed thereinconfigured to receive an end portion of a photovoltaic module returnflange.

In still a further embodiment, the photovoltaic module frame slot of theat least one ballast tray support bracket comprises a straight portionconnected to a circular recess, the straight portion of the photovoltaicmodule frame slot configured to accommodate an insertion of the endportion of the photovoltaic module return flange into the photovoltaicmodule frame slot, and the circular recess of the photovoltaic moduleframe slot configured to accommodate a rotation of the end portion ofthe photovoltaic module return flange within the photovoltaic moduleframe slot after the end portion of the photovoltaic module returnflange has been inserted into the photovoltaic module frame slot.

In yet a further embodiment, the photovoltaic module frame slot of theat least one ballast tray support bracket is bounded by one or moreteeth that are configured to bite into the photovoltaic module returnflange after the end portion of the photovoltaic module return flangehas been rotated into place, thereby ensuring an electrical bond andfrictional contact between the photovoltaic module return flange and theat least one ballast tray support bracket.

In still a further embodiment, the photovoltaic module frame slot of theat least one ballast tray support bracket is bounded by at least oneangled wall portion so as to accommodate the rotation of the end portionof the photovoltaic module return flange within the photovoltaic moduleframe slot.

In still a further embodiment, the at least one ballast tray supportbracket is configured to bridge two of the plurality of rows of thephotovoltaic modules, and the at least one ballast tray support bracketis configured to provide grounding between the two of the plurality ofrows of the photovoltaic modules and grounding of the ballast tray tothe array.

It is to be understood that the foregoing general description and thefollowing detailed description of the present invention are merelyexemplary and explanatory in nature. As such, the foregoing generaldescription and the following detailed description of the inventionshould not be construed to limit the scope of the appended claims in anysense.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described, by way of example, with referenceto the accompanying drawings, in which:

FIG. 1 is a perspective view of an array of photovoltaic (PV) modulesutilizing a mounting system according to a first embodiment of thepresent invention, wherein each of the PV modules is supported in aportrait orientation;

FIG. 2 is an enlarged perspective view of a portion of FIG. 1, showingsupport members of the mounting system;

FIG. 3 is a top/rear perspective view of a support member that is usedin conjunction with the PV array of FIG. 1;

FIG. 4 is a top/front perspective view of the support member of FIG. 3;

FIG. 5 is a bottom perspective view of the support member of FIGS. 3 and4;

FIG. 6 is a rear elevational view of the support member of FIGS. 3 to 5;

FIG. 7 is another perspective view of an alternative version of thearray of PV modules shown in FIG. 1 but wherein the PV modules aresecured in a different orientation;

FIG. 8 is a perspective view of an array according to a secondembodiment of the present invention;

FIG. 9 is a perspective view of an array according to a third embodimentof the present invention;

FIG. 10 is a side elevational view of the array of FIG. 9;

FIG. 11 is a perspective view of a support member of the array of FIGS.9 and 10;

FIG. 12 is a fragmented cross sectional view showing an attachmentsystem for securing the PV modules of the array of FIGS. 9 and 10;

FIG. 12A is a fragmented cross sectional view similar to FIG. 12 butshowing an alternative attachment system;

FIG. 13 is another perspective view of an alternative version of thearray of PV modules shown in FIGS. 9 to 11 but wherein the PV modulesare secured in a different orientation;

FIG. 14 is a perspective view of an array according to a fourthembodiment of the present invention;

FIG. 15 is an enlarged perspective view of an encircled portion of FIG.14 (Detail A), showing a support assembly of the mounting system;

FIG. 16 is a side elevational view of the array of FIG. 14;

FIG. 17 is a top/rear perspective view of one of the support assembliesof FIGS. 14-16;

FIG. 18 is a top/front perspective view of the support assembly of FIG.17, wherein the rotatable clamp subassemblies have been removed from thefirst and second upright support members so that certain features of thebody portion of the support assembly can be more clearly illustrated;

FIG. 19 is a bottom perspective view of the body portion of the supportassembly of FIG. 18;

FIG. 20 is a front elevation view of the body portion of the supportassembly of FIG. 18;

FIG. 21 is a rear elevation view of the body portion of the supportassembly of FIG. 18;

FIG. 22 is a side elevation view of the body portion of the supportassembly of FIG. 18;

FIG. 23 is an exploded perspective view of one of the support assembliesof FIGS. 14-16 and a wind deflector;

FIG. 24 is another perspective view of an alternative version of thearray of PV modules shown in FIG. 14 but wherein the PV modules aresecured in a different orientation;

FIG. 25 is an exploded perspective view of a first type of clampsubassembly of the support assembly;

FIG. 26 is an exploded perspective view of a second type of clampsubassembly of the support assembly;

FIG. 27 is a partial sectional view illustrating the second type ofclamp subassembly of the support assembly attached to a PV module,wherein the section is cut along the cutting-plane line A-A in FIG. 15;

FIG. 28 is an exploded perspective view of a third type of clampsubassembly of the support assembly;

FIG. 29 is a partial sectional view of the third type of clampsubassembly of the support assembly, wherein the section is cut alongthe cutting-plane line B-B in FIG. 30;

FIG. 30 is a partial top plan view of adjacent PV modules supportedusing the third type of clamp subassembly of the support assembly;

FIG. 31 is yet another perspective view of the alternative version ofthe array of PV modules shown in FIG. 24 but wherein the northernmostsupport assemblies are tucked under the northernmost row of PV modules;

FIG. 32 is a partial sectional view of the base portion of the supportassembly illustrating a gasket on the bottom of the base portion,wherein the section is cut along the cutting-plane line C-C in FIG. 17;

FIG. 33 is an enlarged partial sectional view of an encircled portion ofFIG. 29 (Detail B), showing a bonding clamp member of the clampsubassembly of FIG. 29 in more detail;

FIG. 34 is a perspective view of an array of photovoltaic (PV) modulesutilizing a mounting system according to another embodiment of thepresent invention, wherein each of the PV modules is supported in alandscape orientation;

FIG. 35 is an enlarged perspective view of an encircled portion of FIG.34 (Detail “C”), showing a support assembly of the mounting system;

FIG. 36 is a side elevational view of the array of FIG. 34;

FIG. 37 is an enlarged elevational view of an encircled portion of FIG.36 (Detail “D”), showing a support assembly of the mounting system;

FIG. 38 is a top/rear perspective view of one of the support assembliesof FIG. 34;

FIG. 39 is an enlarged perspective view of an encircled portion of FIG.38 (Detail “E”), showing a wire clip slot and weep hole of the supportassembly;

FIG. 40 is a top/front perspective view of the support assembly of FIG.38, wherein the rotatable clamp subassemblies have been removed from thefirst and second upright support members so that certain features of thebody portion of the support assembly can be more clearly illustrated;

FIG. 41 is a bottom perspective view of the body portion of the supportassembly of FIG. 40;

FIG. 42 is a front elevation view of the body portion of the supportassembly of FIG. 40;

FIG. 43 is a rear elevation view of the body portion of the supportassembly of FIG. 40;

FIG. 44 is a side elevation view of the body portion of the supportassembly of FIG. 40;

FIG. 45 is an exploded perspective view of one of the support assembliesof FIG. 34 and a ballast tray and wind deflector;

FIG. 46 is another perspective view of the array of FIG. 34;

FIG. 47 is an exploded perspective view of a clamp subassembly of thesupport assemblies;

FIG. 48 is a partial sectional view illustrating the clamp subassemblyof the support assembly attached to a PV module;

FIG. 49 is still another perspective view of the array of FIG. 34;

FIG. 50 is yet another perspective view of the array of FIG. 34, whereinthe underside of the array is illustrated therein;

FIG. 51 is a side elevational view of the array of FIG. 49;

FIG. 52 is still another perspective view of the array of FIG. 34,wherein the underside of the array is illustrated from a differentviewing angle;

FIG. 53 is an enlarged perspective view of an encircled portion of FIG.52 (Detail “F”), showing a ballast tray support bracket of the mountingsystem;

FIG. 54 is yet another perspective view of the array of FIG. 34;

FIG. 55 is an enlarged perspective view of an encircled portion of FIG.54 (Detail “G”), showing the engagement of a ballast tray with a supportassembly;

FIG. 56 is still another perspective view of the array of FIG. 34,wherein the underside of the array is illustrated from yet a differentviewing angle;

FIG. 57 is yet another perspective view of the array of FIG. 34;

FIG. 58 is an enlarged perspective view of an encircled portion of FIG.57 (Detail “H”), showing a ballast tray support bracket of the mountingsystem;

FIG. 59 is a side elevational view of one of the ballast tray supportbrackets of FIG. 34;

FIG. 60 is an exploded perspective view of the ballast tray supportbracket of FIG. 59;

FIG. 61 is a rear perspective view of one of the support assemblies ofFIG. 34, wherein the attachment of wire clips to the support assembly isillustrated;

FIG. 62 is an enlarged perspective view of an encircled portion of FIG.61 (Detail “I”), showing the wire clips attached to the supportassembly;

FIG. 63 is an enlarged perspective view similar to that of FIG. 62(Detail “J”), except that the wire clips are shown exploded from thesupport assembly;

FIG. 64 is an enlarged perspective view similar to FIG. 53, illustratingan alternative embodiment of the ballast tray support bracket;

FIG. 65 is an enlarged perspective view similar to FIG. 58, illustratingthe alternative embodiment of the ballast tray support bracket depictedin FIG. 64;

FIG. 66 is a side elevational view of the alternative embodiment of theballast tray support bracket depicted in FIGS. 64 and 65;

FIG. 67 is an exploded perspective view of the alternative embodiment ofthe ballast tray support bracket depicted in FIGS. 64 and 65;

FIG. 68 is a side view illustrating the installation angle of a bottomreturn flange of a photovoltaic module in the slot of the ballast traysupport bracket; and

FIG. 69 is another side view illustrating the final installation angleof the bottom return flange of the photovoltaic module in the slot ofthe ballast tray support bracket where the teeth bordering the slot biteinto the bottom return flange.

It should be understood that the appended drawings are not necessarilyto scale, presenting a somewhat simplified representation of variouspreferred features illustrative of the basic principles of theinvention. The specific design features of the mounting systems asdisclosed herein, including, for example, specific dimensions and shapesof the various components will be determined in part by the particularintended application and use environment. Certain features of theillustrated embodiments have been enlarged or distorted relative toothers to facilitate visualization and clear understanding. Inparticular, thin features may be thickened, for example, for clarity orillustration. All references to direction and position, unless otherwiseindicated, refer to the orientation of the mounting systems illustratedin the drawings. In general, up or upward refers to an upward directionwithin the plane of the paper in FIG. 6 and down or downward refers to adownward direction within the plane of the paper in FIG. 6. In general,front or forward refers to a direction towards the south and towards theleft within the plane of the paper in FIG. 1 and rear or rearward refersto a direction towards the north and towards the right within the planeof the paper in FIG. 1.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

It will be apparent to those skilled in the art, that is, to those whohave knowledge or experience in this area of technology, that many usesand design variations are possible for the improved mounting systems andmethods disclosed herein. The following detailed discussion of variousalternative and preferred embodiments will illustrate the generalprinciples of the invention with regard to the specific application ofrooftop mounted photovoltaic (PV) modules that are in the form ofrectangular-shaped panels. Other embodiments suitable for otherapplications will be apparent to those skilled in the art given thebenefit of this disclosure such as for example, ground mounted PVmodules and/or PV modules having different shapes.

FIGS. 1 and 2 illustrate a photovoltaic system 10 according to a firstembodiment of the present invention. The illustrated photovoltaic systemor array 10 includes an array of solar panels or PV modules 12 mountedto a substantially flat support surface 14 (pitch range of about 0degrees to about 5 degrees—see e.g., FIG. 6) in the form of a buildingrooftop 14 by a mounting system or assembly 16 according to the presentinvention. The illustrated mounting system 16 includes a plurality ofsupport members 18 that rest on the support surface 14 and support andorient the PV modules 12 above the support surface 14 and a plurality ofballasts 20 in the form of ballast blocks that weight the supportmembers 18 to the support surface 14 to maintain the position of thesupport members 18 on the support surface 14. The illustrated PV array10 has each of the rectangular shaped PV modules 12 oriented in aportrait orientation, that is, with the longest axis of the PV modules12 extending in a forward-rearward direction which is typically thesouth-north direction. It is noted, however, that the PV modules 12 canalternatively be oriented by the support members 18 in a landscapeorientation, that is, with the longest axis of the PV modules 12extending in a lateral or side-to-side direction which is typically theeast-west direction (see FIG. 7). In either the portrait or landscapeorientations, the illustrated PV modules are supported in an inclinedposition such that the forward end of each PV module 12 is positionedlower than its rearward end so that typically the southern end ispositioned lower than the northern end.

Each illustrated PV module 12 is supported by a plurality of the supportmembers 18. At least three of the support members 18 must be utilizedfor each of the PV modules 12 in order to establish a desired plane forthe PV modules 12. For the illustrated rectangular-shaped PV modules 12,at least four of the support members 18 are preferably utilized tosupport each of the PV modules so that they can be positioned at or neareach corner of the rectangular-shaped PV modules 12. Each support member18 supports at least one of the PV modules 12 but some of theillustrated support members 18 support more than one of the PV modules12. The illustrated PV modules 12 are secured to the support members 18(as described in more detail hereinafter) but each the support members18 is not directly secured to any of the other support members 18. It isnoted that while there is not a direct structural connection between thesupport members 18, the support members 18 are indirectly connected bythe PV modules 12 in a structural manner. That is, they are connected ina load carrying manner. It is noted that non-load bearing componentssuch as wind shields and the like can also be supported by the supportmembers 18 as discussed in more detail hereinafter. Thus, the supportmembers 18 are only structurally connected to one another through the PVmodules 12. Securing the support members 18 at or near the corners of PVmodules 12, and not directly connected to one another, allows themounting system 16 to be used with PV modules 12 of any width and lengthwithout requiring customization or modification to the support members18 or the PV modules 12. Thus a common support member 18 can be used inmany applications to mount many different models of PV modules 12. Also,the illustrated support members 18 are not fastened to the supportsurface 14 and simply rest on the support surface 14 as they areweighted in place by the ballast 20. Therefore the support members 18 donot penetrate the roof membrane of the support surface 14.

The illustrated mounting system 16 has the flexibility to be configuredto add resistance to wind loads at most installation sites. To furtherresist winds from the north which create the greatest need for ballastweight, one or more of the support members 18 can be placed in betweenthe support members 18 at the corners of the PV module 12 to addadditional ballast 20 and block wind from blowing underneath the PVmodule to create uplift. The additional support member also creates theability for ballast 20 in the form of a concrete block to be placed onits side and straddling two of the support members 18 to further createa wind barrier which prevents wind from blowing underneath the PV module12 to create uplift. The illustrated PV array 10 shows that supportmembers and straddling ballast 20 can be utilized to fully block therearward end of the PV array 10 (see e.g., FIG. 1).

As shown in FIGS. 3 to 6, each of the illustrated support members 18 canbe quickly and removably attached to the PV module 12 without toolsusing an attachment system 21. The illustrated attachment system 21 isin the form of pivoting hooks 22. In the illustrated embodiment, up tofour pivoting hooks 22 can be secured at the forward end and therearward end of the support member 18. The illustrated hooks 22 areadapted to engage and secure a lower flange 24 of the PV module 12. Bothends of the illustrated support member 18 are provided with a pair oflaterally spaced-apart upper holes 26 on each side of the support membercenterline 28 so that the hooks 22 can be located to engage PV moduleflanges 24 in both directions and having a variety of different widthsso that customization of the flange 24, hook 22, or support member 18 isnot required. Both ends of the illustrated support member 18 are alsoprovided with a pair of laterally spaced apart lower holes 30 on eachside of the support member centerline 28 for attachment of the hooks 22.More than two holes 26, 30 can be utilized if it is desired toaccommodate a wider variety of widths for the PV module lower flange 24.It is noted that any other suitable quantity and/or locations for theopenings 26, 30 can be utilized depending on how much flexibility inpositioning the hooks 22 is desired.

To secure the PV module 12 to the illustrated support member 18, thehook 22 is first attached to the support member 18 by inserting a firstremovable fastener 32 through an upper hole 34 of the hook 22 and intoone of the upper holes 26 in the support member 18 so that the hook 22is pivotably secured to the support member 18. That is, the hook 22 ispivotable relative to the support member 18 about the rivet 32. Theillustrated fastener 32 is a plastic push rivet. Suitable plastic pushrivets include TR and TRM rivets available from Richco Inc. of MortonGrove, Ill. It is noted that any other suitable fasteners 32 canalternatively be utilized in place of the illustrated push rivets 32.With the hook 22 pivotably attached to the support member 18, the PVmodule 12 is placed onto the support member 18 and the PV module 12 issecured to the support member 18 by pivoting the hook 22 about the rivet(clockwise in FIG. 6) until the hook 22 is vertical and its hook portion36 is above and pressing down on the lower flange 24 of the PV module12. A second removable fastener in the form of a plastic push rivet isinserted through a lower hole 38 of the hook 22 and into one of thelower holes 30 in the support member 18 so that the hook 22 is no longerpivotable relative to the support member 18. The illustrated attachmentsystem is low cost, universal, quick, easy, and robust. It is notedhowever, that any other suitable attachment system 21 can alternativelybe utilized to secure the PV modules 12 to the support members 18 ifdesired. For example, one alternative to the illustrated attachmentsystem 21 is to replace the push rivet 32 with a snap-in feature orfeatures integrally molded into the hook 22 that snaps into the upperholes 26 and/or locks into the lower holes 30 the hook 22 is beingpivoted into place. Also for example, another alternative to theillustrated attachment system 21 is to replace the hook 22 with a slidemechanism that slides across the top of the support member 18 after thePV module 12 is in place to trap the PV module's lower flange 24. Theslider of the slide mechanism could be held in place by snap-infeatures, fasteners, or the like. As an additional alternative to theillustrated attachment system 21, the hooks 22 may be replaced with oneor more clamping members that include integrated grounding means.

The illustrated support member 18 is designed to be entirely comprisedof plastic and can be manufactured by thermoforming by using chamfers,gussets, large radii, and large draft angles. A suitable plastic is HighMolecular Weight Polyethylene (HMWPE) with UV inhibitor. It is notedhowever, that the support member 18 can alternatively comprise othermaterials and/or can be manufactured by other methods such as, forexample, injection molding or the like. Plastic enables desired complexshapes to be produced at relatively low cost and has other advantagesover prior art products made of aluminum, galvanized metal, andstainless steel materials. For example, plastic is rustproof, can bemade with 100% recycled materials and is 100% recyclable, does notrequire electrical grounding, and is harmless on the roof membrane, andis low cost.

The illustrated support member 18 is formed of thin walls and includes abottom wall 40 surrounded by hollow forward, rearward and side walls 42,44, 46 to form a central upward facing cavity 48. The cavity 48 is sizedand shaped for receiving the ballast as described in more detailhereinafter. The illustrated support member 18 includes an outerperipheral flange 50 that has an upturned outer edge or lip that isstepped slightly above the support surface 14 to prevent the edge fromdamaging the support surface 14 particularly when it is a thin roofmembrane. These upturned edges also add strength to flange 50. Theillustrated support member 18 utilizes built-in ribs 52 and a variablewall thickness to enable the support member 18 to adequately support thePV modules 12, and other loads such as large snow loads, with thin wallsand low cost commodity plastics. The hollow shape and large draft anglesallow for the illustrated support members 18 to be nested together whenstacked to lower shipping and handling costs.

The illustrated hollow forward wall 42 forms a first or forward supportsurface 54 at its top and the hollow rearward wall 44 forms a second orrearward support surface 56 at its top. The first support surface 54 issized and shaped to support the rearward ends of the PV modules 12. Thesecond support surface 56 is sized and shaped to support the forwardends of the PV modules 12. The first support surface 54 is located at aheight greater than a height of the second support surface 56 so thatthe PV modules 12 resting thereon are inclined. The difference in heightas well as the length of the PV module 12 determines the angle ofinclination of the PV module 12. The tilt angle is preferably within therange of 10 degrees to 12 degrees depending on the dimension of the PVmodule 12. The illustrated first and second support surfaces 54, 56 areeach inclined in the same direction (downward in a forward direction) toaccount for the inclination of the PV modules 12. The illustratedsupport member 18 is sized and shaped to automatically align the PVmodules 12 relative to one another when supported on the supportsurfaces 54, 56. The illustrated support member 18 includes variousfeatures to align the PV modules 12 in both the east/west direction(that is, the lateral direction) and the north/south direction (that is,the rearward/forward direction). By using these features to trap orprevent movement of the PV module 12 relative to the support member 18in all directions but up and the support surfaces 54, 56 preventdownward movement of the PV module 12, the attachment system 21 onlyneeds to keep the PV module 12 from moving up relative to the supportmember 18.

The illustrated first support surface 54 is provided with a centrallylocated wall (i.e., a PV module spacer) that forms opposed first andsecond abutments 58, 60 that face in laterally outward directions (thatis, in directions horizontal and perpendicular to the longitudinalcenterline 28 of the support member 18). With a side flange 62, whichconnects the lower flange 24, engaging the abutment 58, 60 the PV module12 supported on the first support surface 54 is automatically positionedand aligned to the longitudinal centerline 28 of the support member 18.The illustrated second support surface 56 is provided with a centrallylocated wall (i.e., a PV module spacer) that forms opposed first andsecond abutments 64, 66 that face in laterally outward directions (thatis, in directions horizontal and perpendicular to the longitudinalcenterline 28 of the support member 18). With the side flange 62 of thePV module 12 engaging the abutment 64, 66 the PV module 12 supported onthe second engagement surface 56 is automatically positioned and alignedto the longitudinal centerline 28 of the support member 18. The hollowside walls 46 form rearward facing abutments 68 at their rear ends. Withthe side flange 62 of the PV module 12 engaging the rear facingabutments 68, the PV module 12 supported on the second engagementsurface 56 is automatically positioned and aligned in theforward/rearward direction relative to the support member 18. Theillustrated abutments 68 are located near the second support surface 56but spaced forward of the second support surface 56 (see e.g., FIG. 3).

The illustrated side walls 46 of the support member 18 have cutouts ornotches 70 to hold a ballast 20 in the form of a block positioned on itsside and extending laterally, either across one support member 18 orstraddling two support members 18 (as described in more detailhereinafter). The illustrated notches 70 are located near the forwardwall 42 but are spaced rearwardly from the forward wall 42. Positionedin this manner, the ballast 20 effectively blocks the wind and addsballast weight, without shading any PV module 12 located to the north.An alternative to the illustrated cutouts 70 is to mold a suitablecavity for holding the ballast without cutting out the surfaces of theside walls 46.

The illustrated support members 18 also have holes 72 that accept one ofmany commercially available wire management clips to provide built-inwire management. Suitable wire management cable ties include WIT-40LARand WIT-RRA available from Richco Inc. of Morton Grove, Ill. Analternative is to mold channels into the support member 18 through whichwires from the PV modules 12 can be run.

The bottom surface of the illustrated bottom wall 40 has “tread” orother raised features 74 that increase the traction (or coefficient offriction) between the support member 18 and the flat support surface 14.This increased traction reduces the amount of ballast weight required tokeep the support member 18 from sliding relative to the support surface14 during wind loads. Alternatively and/or additionally, a rubber pad,feet, or the like (such as, for example EPDM) can be provided underneaththe support member 18 to further increase the coefficient of friction.Another alternative is to use a double sided adhesive pad so that thesupport member 18 adheres to the support surface 14. Yet anotheralternative is to use butyl tape or the like under the support member 18when the support surface 14 is a building rooftop so that the butyl willadhere to the rooftop surface once the temperature is high on a hot day,similar to asphalt shingles.

Each of the illustrated support members 18 can carry up to three of theballasts 20 in the form of standard off-the-shelf, commerciallyavailable solid concrete blocks or roof pavers. The illustrated ballastblocks are of the size 4″×8″×16″ and weigh about 31.5 pounds each basedon ASTM Designation C1491-01a. In the illustrated embodiment, two of theballast blocks are stacked and longitudinally extend near a rearward endof the support member 18 and one is positioned on its side and laterallyextends near a forward end of the support member 18. The threeillustrated ballast blocks provide about 94.5 lbs. of ballast to thesupport member 18. It is noted that any other suitable quantity,position and orientation of the blocks can alternatively be utilized asdesired for a particular installation. For example, some of theillustrated support members 18 have two ballast blocks that are stackedand longitudinally extend near a forward end of the support member 18.It is noted that any other suitable type, shape, quantity, orientation,weight, and/or size of ballast 20 can alternatively be utilized. Forexample, the ballast 20 can be in the form of water bladders, sandfilled containers, gravel filled containers, or the like. Advantages ofwater over other weight providing materials such as concrete are that itis free, easy to pump to the mounting site, safe on the roof membrane orother support surface 14, can be easily drained when decommissioning thePV array 10, and has no impact on the environment. The water bladderwould be sealed to prevent evaporation and undesirable bacteria to causea nuisance. In order to account for expansion and contraction due tofreezing/thawing and temperature changes, airspace could be maintainedabove the water or the bladder could be flexible to expand and contract.

As best shown in FIG. 7, the PV modules 12 can be mounted using the samesupport members 18 to mount the PV modules 12 in the landscapeorientation rather than the portrait orientation. In this portraitorientation, the PV modules 12 are mounted directly to the supportmembers 18 using an attachment system 21 utilizing mounting holes 92provided by the manufacturer of the PV module 12 in the lower flange 24of the PV module 12 (see FIG. 12A). A plastic push rivet is one way tofasten the PV module 12 to the support member 18 but any other suitablefastener, clamp, clip, latch or the like can alternatively be utilized.This alternative landscape orientation can be used in cases where themanufacturer of the PV module 12 requires that the mounting holes 92 ofthe PV module 12 be used or in cases where wind loads require weightexceeding the provisions of the portrait orientation configurationdescribed above.

FIG. 8 illustrates a PV array 10 according to a second embodiment of thepresent invention. This embodiment illustrates that the support members18 can have other suitable forms. The support member 18 of thisembodiment includes a hollow plastic reservoir or tank 76 that can befilled with water for ballast weight. It is noted that the supportmember 18 described hereinabove with regard to the first embodiment ofthe invention could be modified to accomplish this with very littlechange. The void or cavity 48 where the concrete ballast blocks restwould be instead filled by the reservoir 76. The illustrated reservoir76 is formed hollow, filled with water, and sealed closed. A removablecap is provided to seal closed the inlet used to fill the reservoir 76.An air gap within the reservoir 76 allows for water volume changes dueto freezing and thawing. The illustrated PV module 12 is supported atfour locations by identical feet 78. The attachment system 21 securesthe feet 78 to the mounting holes in the PV module's lower flange 24.The attachment system 21 can be any suitable fastener (such as bolt andnuts, plastic push rivets, or the like), clamp, clip, latch, or thelike. It is noted that the tank 76 can naturally create a wind barrierto prevent uplift due to wind blowing below the PV modules 12.

FIGS. 9 to 12 illustrate a PV array 10 according to a third embodimentof the invention. This embodiment also illustrates that the supportmembers 18 can have other suitable forms. The support member 18 of thisembodiment is formed so that the ballast 20, which is in the form of aconcrete block, can lay flat in a transverse direction centrally on thesupport member 18. The support member 18 also does not have the abutmentforming walls so that the lower flange 24 of the PV modules can rest onthe support surfaces 54, 56 and are secured to the support member 18 bythe attachment system 21 in the form of a clamp assembly 80. Theillustrated clamp assembly 80 (see FIG. 12) includes a threaded stud orbolt 82 that vertically extends through an opening 84 at the supportsurface 54, 56. A clamping element 86 is secured to the bolt 82 with anut 88 to form a compression clamp which secures the PV module 12 to theengagement surface 54, 56 of the support member 18 and the clampingelement 86. The illustrated clamp assembly 80 includes a metal plate 89in the form of a disc to secure the stud 82 to the support member 18 butthe stud 82 can alternatively be secured in any other suitable manner.The illustrated PV module 12 engages the metal plate 89 and can beconveniently used as a grounding point for the PV Module 12 if desired.Suitable compression clamp assemblies 80 are S-5-PV clamps which areavailable from Metal Roof Innovations, Ltd, of Colorado Springs, Colo.It is noted that the attachment system 21 can alternatively be any othersuitable fastener (such as bolt and nuts, plastic push rivets, or thelike), clamp, clip, latch, or the like. FIG. 12A illustrates analternative attachment system 21 which includes a bolt and nut 90, 91with the bolt 90 extending through an opening 92 in the lower flange 24of the PV module 12. This attachment system can be particularly usefulwhen the manufacturer of the PV module 12 requires mounting through theflange openings 92.

This embodiment also includes a rear wind shield or blocker 94 supportedby the support members 18 at the rear end of the array system 10 inorder to reduce wind load. The illustrated wind shield 94 is held by therearward most ones of the support members 18 and is shaped and spaced adistance from rearward most ones of the photovoltaic modules 12 todeflect wind, blowing from the north, up and over the array ofphotovoltaic modules 12 rather than under the photovoltaic modules 12 inorder to reduce wind load. The illustrated wind shield 94 extends thefull width of the PV array 10 between the outer most lateral edges ofthe PV modules 12 but any other suitable distance can alternatively beutilized and/or more than one wind shield 94 can be utilized to coverthe desired distance. The illustrated wind shield 94 has an arcuateportion forming a concave surface facing rearward and upper and lowerflange portions for securing the wind shield 94 to the support members18. The illustrated upper flange extends in a direction opposed to theconvex surface and the illustrated lower flange extends in the directionof the convex surface. The illustrated wind shield 94 is positioned onthe rear side of the rearward walls 44 of the rearward most supportmembers 18. The illustrated rearward walls 44 are convex to cooperatewith the arcuate portion of the wind shield 94. It is noted that thisshape can be effective to deflect a portion of the wind even when thewind shield 94 is not utilized. The illustrated upper flange engages aportion of the second support surface 56 while the illustrated lowerflange engages a ledge located at the bottom of the rearward wall 44.The wind shield 94 can be held by the support members 18 in any suitablemanner. The illustrated wind shield 94 is positioned a distance Drearwardly from the rearward most ones of the photovoltaic modules 12which is at least 1.5 times a maximum height H of the rearward most onesof the photovoltaic modules 12 so that wind is deflected up and over thearray of photovoltaic modules 12. Constructed in this manner, it is notnecessary to close off the entire gap below the rear edge of therearward most PV modules 12. It is noted that the rear wind shield 94can be eliminated if desired.

The wind shield 94 is preferably extruded of a lightweight plasticmaterial but it can alternatively be formed in any other suitable mannerand/or can alternatively comprise any other suitable material. Thelightweight plastic material can be of any suitable type. The windshield 94 is preferably lightweight and non-structural, that is, it doesnot significantly increase the structural strength or stiffness of thearray system 10.

The illustrated PV array system 10 also includes a front wind shield 94Awhich is forward facing and positioned at the forward side of the arraysystem 10 to protect against any wind blowing from the south. The frontwind shield 94A is located at the front side of the forward most ones ofthe PV modules 12 and substantially closes the gap under the front edge.The illustrated front wind shield 94A extends the full width of the PVarray 10 between the outer most lateral edges of the PV modules 12 butany other suitable distance can alternatively be utilized and/or morethan one wind shield 94A can be utilized to cover the desired distance.The front side of the rearward walls 44 of the support members 18 aresized and shaped with ledges and a convex portion to cooperate with thefront wind shield 94A in a manner similar to the way the rear side ofthe rearward walls 44 cooperate with the rear wind shield 94. The frontwind shield 94A is preferably constructed identical to the rear windshield 94 so that the advantages of common parts can be utilized. It isnoted that the front wind shield 94A can be eliminated if desired.

The illustrated PV array system 10 further includes intermediate windshields 94B which are rearward facing and positioned between the forwardand rearward sides of the array system 10 to protect against any windblowing from the north at a steep angle or the like. While these windshields 94B may not be effective to deflect all wind up and over the PVmodules 12, they can still reduce the amount of wind that passes underthe PV modules 12. The intermediate wind shields 94B are located atintermediate ones of the support members 18. The illustratedintermediate wind shields 94B extend the full width of the PV array 10between the outer most lateral edges of the PV modules 12 but any othersuitable distance can alternatively be utilized and/or more than onewind shield 94B can be utilized to cover the desired distance. Theillustrated rear sides of forward walls 42 of the support members 18 aresized and shaped with ledges and to cooperate with a pair of theintermediate wind shields 94B one above the other in a manner similar tothe way the rearward walls 44 cooperate with the rear wind shield 94.Configured in this manner the intermediate wind shields 94Bsubstantially close the entire gap below the rearward side of PV modules12 located between the forward and rearward sides of the PV array system10. The intermediate wind shields 94B are preferably constructedidentical to the rear wind shield 94 so that the advantages of commonparts can be utilized. It is noted that the intermediate wind shields94B can be eliminated if desired.

As best shown in FIG. 13, the PV modules 12 can be mounted using thesame support members 18 described-above to mount the PV modules 12 inthe portrait orientation rather than the landscape orientation.

FIGS. 14-16 illustrate a photovoltaic system or array 100 according to afourth embodiment of the present invention. As described above for thepreceding embodiments, the illustrated photovoltaic system or array 100includes an array of solar panels or PV modules 102 mounted to asubstantially flat support surface 108 (see FIG. 16) in the form of abuilding rooftop 108 by a mounting system or assembly 110. In FIG. 14,there are two rows of PV modules 102 illustrated for exemplary purposes,each of the two rows having three (3) PV modules 102 disposed therein.The illustrated mounting system 110 includes a plurality of supportassemblies 112 (or support assembly members 112) that rest on thesupport surface 108 and support and orient the PV modules 102 above thesupport surface 108 and a plurality of ballasts 114 in the form ofballast blocks that weight the support assemblies 112 to the supportsurface 108 to maintain the position of the support assemblies 112 onthe support surface 108. As shown in FIG. 14, the four (4) supportassemblies 112 disposed in the middle of the PV array 100 bridge the tworows of PV modules 102. The PV array 100 illustrated in FIGS. 14-16 haseach of the rectangular shaped PV modules 102 oriented in a landscapeorientation, that is, with the longest axis of the PV modules 102extending in a lateral or side-to-side direction which is typically theeast-west direction. It is noted, however, that the PV modules 102 canalternatively be oriented by the support assemblies 112 in a portraitorientation, that is, with the longest axis of the PV modules 102extending in a forward-rearward direction which is typically thesouth-north direction (see FIG. 24). In either the landscape or portraitorientations, the illustrated PV modules 102 are supported in aninclined position such that the forward end of each PV module 102 ispositioned lower than its rearward end so that typically the southernend is positioned lower than the northern end.

As shown in the perspective views of FIGS. 14 and 24, each illustratedPV module 102 is supported by a plurality of the support assemblies 112(performing a function similar to the support members 18 describedabove). At least three of the support assemblies 112 must be utilizedfor each of the PV modules 102 in order to establish a desired plane forthe PV modules 102. For the illustrated rectangular-shaped PV modules102, at least four of the support assemblies 112 are preferably utilizedto support each of the PV modules 102 so that they can be positioned ator near each corner of the rectangular-shaped PV modules 102. Eachsupport assembly 112 supports at least one of the PV modules 102 butsome of the illustrated support assemblies 112 support more than one ofthe PV modules 102. The illustrated PV modules 102 are secured to thesupport assemblies 112 (as described in more detail hereinafter) buteach of the support assemblies 112 is not directly secured to any of theother support assemblies 112 (e.g., there is no rail member connectingone support assembly to another support assembly). As described abovefor the support members 18, it is noted that while there is not a directstructural connection between the support assemblies 112, the supportassemblies 112 are indirectly connected by the PV modules 102 in astructural manner (i.e., they are connected in a load carrying manner).Also, similar to that described above for the preceding embodiments, itis further noted that non-load bearing components, such as wind shields(or wind deflectors), wire trays, and the like can also be supported bythe support assemblies 112 as described in more detail hereinafter.Thus, the support assemblies 112 are only structurally connected to oneanother through the PV modules 102. Securing the support assemblies 112at or near the corners of PV modules 102, and not directly connectingthem to one another, allows the mounting system 110 to be used with PVmodules 102 of any width and length without requiring customization ormodification to the support assemblies 112 or the PV modules 102. Thus,a common support assembly 112 can be used in many applications to mountmany different models of PV modules 102. Also, the illustrated supportassemblies 112 are not fastened to the support surface 108 and simplyrest on the support surface 108 as they are weighted in place by theballasts 114. Therefore, the support assemblies 112 do not penetrate theroof membrane of the support surface 108, nor do they require fastenersthat penetrate the roof membrane of the support surface 108. That is,the support assembly 112 is in the form of a non-penetrating supportdevice that does not penetrate the support surface 108.

Similar to that described above for the support member 18, with theexception of the clamping assembly components, the support assembly 112can be formed entirely of polymer or plastic. That is, the body portionof the support assembly 112 (see FIGS. 18-22), which includes the baseportion 116, the first upright support member 120, and the secondupright support member 134 can be formed entirely of polymer or plastic,and components 116, 120, 134 can all be molded as an integral unit froma polymer or plastic. One suitable polymer or plastic for the body ofthe support assembly 112 is acrylonitrile styrene acrylate (ASA) Luran®by Styrolution. The use of a highly durable plastic, such as Luran®,ensures that the support assembly 112 will be able to withstand thetoughest rooftop exposure for twenty-five (25) years or more (i.e., thesupport assembly 112 has substantial weatherability). Advantageously,plastic is harmless on the roof membrane, it is non-corrosive, it isnon-conductive (i.e., it does not pose any electrical potential threat),and it has a low cost.

Now, with particular reference to FIGS. 17-22, the structural featuresof the illustrated support assembly 112 will be described in detail. Asbest shown in the perspective views of FIGS. 17 and 18, the supportassembly 112 generally comprises a base portion 116, the base portion116 including a recessed portion 118 for accommodating one or moreballasts 114; a first upright support member 120 coupled to the baseportion 116, the first upright support member 120 having a top surface128, the top surface 128 being disposed at a first elevation E1 relativeto the base portion 116 of the support assembly 112 (i.e., relative tothe bottom surface of the base portion 116—see FIG. 22); and a secondupright support member 134 coupled to the base portion 116, the secondupright support member 134 spaced apart from the first upright supportmember 120 across the recessed portion 118 of the base portion 116, thesecond upright support member 134 having a top surface 142, the topsurface 142 being disposed at a second elevation E2 relative to the baseportion 116 of the support assembly 112 (i.e., relative to the bottomsurface of the base portion 116—see FIG. 22). As shown in the side viewof FIG. 22, the first elevation E1 of the top surface 128 is higher thanthe second elevation E2 of the top surface 142. Also, as illustrated inFIGS. 17 and 18, each of the first and second upright support members120, 134 is provided with a respective peripheral recess 132, 146therearound.

As shown in the top perspective views of FIGS. 17 and 18, the baseportion 116 of the support assembly 112 is provided with a peripheralledge 206 around the periphery thereof. The peripheral ledge 206 of thebase portion 116 circumscribes the recessed portion 118 of the supportassembly, as well as the first and second upright support members 120,134. At the outermost edge of the peripheral ledge 206, the base portion116 is provided with a downturned peripheral edge 208 that circumscribesthe entire support assembly 112 (see e.g., FIGS. 17 and 32). Now,turning to the bottom perspective view of FIG. 19, it can be seen thateach opposed side portion of the peripheral ledge 206 is provided with aplurality of longitudinally spaced apart reinforcement ribs 220 disposedthereunder. The reinforcement ribs 220 structurally support the opposedside portions of the peripheral ledge 206, and more generally, addstructural rigidity to the support assembly as a whole.

Similar to that described above for the support members 18, the recessedportions 118 of the base portions 116 of the support assemblies 112 aredesigned to accommodate a plurality of ballasts 114 (e.g., two (2)ballasts 114 arranged side-by-side as illustrated in FIGS. 14 and 15).In an exemplary embodiment, the ballast blocks 114 are of the size4″×8″×16″ and weigh about 31.5 pounds each based on ASTM DesignationC1491-01a.

As described above for the preceding embodiments, the generally hollowshape and large draft angles of the plastic body portion of the supportassemblies 112 (i.e., the plastic body portion comprising the baseportion 116, the first upright support member 120, and the secondupright support member 134) allow for the illustrated support assemblies112 to be nested together when stacked to lower shipping and handlingcosts.

With continued reference to FIGS. 17-22, it can be seen that the firstupright support member 120 comprises a front wall 122, opposed sidewalls 124, and a rear wall 126. Each of these walls 122, 124, 126 issloped inwardly in an upward direction such that the first uprightsupport member 120 has a generally truncated pyramidal shape. Similarly,the second upright support member 134 comprises a front wall 136,opposed side walls 138, and a rear wall 140. Like the walls 122, 124,126 of the first upright support member 120, the walls 136, 138, 140 ofthe second upright support member 134 are also sloped inwardly in anupward direction so as to also give the second upright support member134 a generally truncated pyramidal shape. However, as shown mostclearly in FIGS. 17 and 18, the pyramidal second upright support member134 has a much smaller footprint and height than the pyramidal firstupright support member 120. While the illustrated first and secondupright support members 120, 134 generally have truncated pyramidalshapes, it is to be understood that other suitable shapes may be usedfor the first and second upright support members 120, 134 such as, forexample, a rectangular shape (i.e., alternative upright support memberscould have a post-like appearance).

As best illustrated in FIG. 18, the first and second upright supportmembers 120, 134 are provided with respective concave notches or pockets130, 144 for receiving respective base portions of respective rotatableclamp subassemblies 154, 156. Referring to the assembled view of FIG.17, it can be seen that the illustrated support assembly 112 comprises afirst rotatable clamp subassembly 154 rotatably coupled to the firstupright support member 120 via a clevis pin 196, which is receivedwithin a clevis pin aperture 129 (see FIG. 22). The first rotatableclamp subassembly 154 is configured to be coupled to one or morephotovoltaic modules 102 (e.g., to the north side of one or morephotovoltaic modules 102, as illustrated in FIG. 14). Similarly, thesecond rotatable clamp subassembly 156 is rotatably coupled to thesecond upright support member 134 via a clevis pin 196, which isreceived within a clevis pin aperture 143 (see FIG. 22). The secondrotatable clamp subassembly 156 is configured to be coupled to one ormore other photovoltaic modules 102 (e.g., to the south side of one ormore photovoltaic modules 102, as illustrated in FIG. 14). In oneembodiment, the clevis pins 196 are in the form of self-lockingimplanted cotter pin (SLIC) type clevis pins that snap into placewithout the need for a cotter pin or other secondary retention part.Advantageously, by eliminating the use of a cotter pin, the SLIC clevispin (or SLIC pin) saves installation time and money. Although, it is tobe understood that other suitable fasteners may also be used to attachthe first and second rotatable clamp subassemblies 154, 156 to theirrespective first and second upright support members 120 and 134. It isto be understood that different ones of the first, second, and thirdclamp subassemblies described hereinafter can be used together in thesame support assembly 112 to accommodate various PV module mountingconfigurations (e.g., first clamp subassembly in notch 130 and secondclamp subassembly in notch 144).

A first type of clamp subassembly (or clamp assembly) used as PV moduleattachment means of the support assembly 112 is illustrated in FIG. 25.As shown in the exploded view of FIG. 25, the first type of clampsubassembly generally comprises a pivotal base member 158 and an upperclamp member 176′, wherein the upper clamp member 176′ is coupled to thepivotal base member 158 by a fastener (e.g., headless-type assembly bolt198 with corresponding nut 200). Referring again to FIG. 25, it can beseen that the pivotal base member 158 further includes a base portion160 with a curved bottom surface 162, and an L-shaped flange portion 166with a flange base portion 168 and an upright portion 172. The flangebase portion 168 of the L-shaped flange portion 166 comprises fastenerapertures 170 for accommodating a fastener (e.g., headless-type assemblybolt or stud 198). In the illustrated embodiment, the fastener apertures170 are provided with a plurality of internal threads for matinglyengaging with the external threads on the bolt 198. In anotherembodiment, the end of the bolt 198 can be embedded in the flange baseportion 168. Advantageously, the centrally disposed bolt 198 extendingfrom the planar base portion 168 is configured to define a clearance gapbetween adjacent PV modules 102 mounted to the clamp subassembly (i.e.,the bolt 198 is used to create a predetermined spacing between the PVmodules 102). A lock washer 240, which has a plurality of smallprojections or protrusions disposed thereon (e.g., semi-sphericalprojections), may be provided between the installed PV modules 102 andthe flange base portion 168. The upright portion 172 of the L-shapedflange portion 166 also comprises a fastener aperture 174 foraccommodating a fastener (e.g., headless-type bolt or stud 202 withcorresponding nut 204, which can be used for securing the top edgeportion of the wind deflector 222 to the support assembly 112—see FIGS.15 and 23). Similar to the fastener aperture 170, the fastener aperture174 of the illustrated embodiment is provided with a plurality ofinternal threads for matingly engaging with the external threads on thebolt 202. In another embodiment, the end of the bolt 202 can be embeddedin the upright portion 172. A lock washer 242, which has a plurality ofsmall projections or protrusions disposed thereon (e.g., semi-sphericalprojections), may be provided between the nut 204 and the uprightportion 172, or the installed wind deflector 222 and the upright portion172.

With combined reference to FIGS. 25-27, it can be seen that the baseportion 168 of the clamp pivotal base member 158 further includes adownwardly sloped flange portion 169 configured to facilitate aninsertion of the PV modules 102 into the clamp subassembly. As shown inFIG. 27, the downwardly sloped flange portion 169 of the clamp pivotalbase member 158 is angled downwardly towards a top surface of theupright support member 120 of the base portion 116 of the supportassembly 112. In addition to facilitating an insertion of the PV modules102 into the clamp subassembly, the downwardly sloped flange portion 169also limits a rotation of the clamp subassembly on the upright supportmember 120 of the base portion 112 (i.e., when the bottom edge of thedownwardly sloped flange portion 169 contacts the top surface of thesupport member 120—see FIG. 27). This rotational limit imposed by thedownwardly sloped flange portion 169 also facilitates the ease ofinstallation of the PV modules 102.

In addition, referring again to FIGS. 25-27, it can be seen that theelevated shelf portion of the base portion 168 of the clamp pivotal basemember 158 comprises a cantilevered edge 171 where it meets the sideflange 106 of the PV module frame (see FIG. 27).

Advantageously, the recess 173 underneath the cantilevered edge 171(refer to FIGS. 25 and 26) enables the clamp subassembly to be coupledwith another accessory of the photovoltaic array.

Still referring to FIG. 25, it can be seen that the upper clamp member176′ generally comprises a plate portion 178′ with a fastener aperture180 disposed therethrough for accommodating a fastener (e.g.,headless-type assembly bolt 198 with corresponding nut 200). In theapproximate middle of the plate portion 178′ of the upper clamp member176′, extending from the bottom surface thereof, a longitudinallyextending protrusion 182′ is provided. The protrusion 182′ is configuredto extend into the gap between adjacent PV modules 102 when the plateportion 178′ is tightened against the top surface of the PV modules 102(e.g., by torqueing nut 200).

A second type of clamp subassembly (or clamp assembly) used as PV moduleattachment means of the support assembly 112 is illustrated in FIGS. 26and 27. As shown in the exploded view of FIG. 26, the second type ofclamp subassembly generally comprises a pivotal base member 158 and anL-shaped side clamp member 226, wherein the L-shaped side clamp member226 is coupled to the pivotal base member 158 by a fastener (e.g.,headless-type assembly bolt 198 with corresponding nut 200). Referringagain to FIG. 26, it can be seen that the structure of the pivotal basemember 158 of the second type of clamp subassembly is generally the sameas that described above for the first type of clamp subassembly.Although, unlike in the first clamp subassembly, the headless-typeassembly bolt 198 in FIG. 26 is disposed in the fastener aperture 170disposed closest to the upright portion 172 of the L-shaped flangeportion 166 of the pivotal base member 158. The components of the secondclamp subassembly for attaching the top edge portion of the winddeflector 222 thereto are also generally the same as that describedabove for the first type of clamp subassembly. As such, no furtherelaboration on these components is required in conjunction with thesecond type of clamp subassembly.

With continued reference to FIG. 26, it can be seen that the L-shapedside clamp member 226 generally comprises a bottom wall 228, opposedside walls 232 connected to the bottom wall 228, and an upper plateportion 234 connected to the upper ends of the opposed side walls 232.The bottom wall 228 of the L-shaped side clamp member 226 comprises afastener aperture 230 disposed therethrough for accommodating a fastener(e.g., headless-type assembly bolt 198 with corresponding nut 200). Theupper plate portion 234 of the L-shaped side clamp member 226 comprisesa fastener aperture 238 disposed therethrough, which is generallyaxially aligned with the fastener aperture 230, for accommodating afastener (e.g., headless-type assembly bolt 198 with corresponding nut200). As shown in FIG. 26, the upper plate portion 234 of the L-shapedside clamp member 226 also includes a chamfered edge 236.

Next, referring primarily to the sectional view of FIG. 27, the mannerin which the second clamp subassembly engages one or more PV modules 102will be described. In this figure, it can be seen that, when theL-shaped side clamp member 226 is tightened against the upper surface ofthe PV module 102 (e.g., by torqueing nut 200), the bottom flange 104 ofthe PV module 102 abuts the upper surface of base portion 160 of thepivotal base member 158, and the side flange 106 of the PV module 102abuts the inner side wall 232 of the L-shaped side clamp member 226. Assuch, the one or more PV modules 102 are clamped into place on thesupport assembly 112.

Advantageously, the clamp subassembly illustrated in FIGS. 26 and 27 iscapable of being used as a universal-type clamp that can be attachedanywhere along a side of a PV module 102. As such, when the clampsubassembly of FIGS. 26 and 27 is used, there is no need for twodifferent types of clamps in the PV module installation (i.e., aseparate mid-clamp and end clamp are not required when the clampsubassembly of FIGS. 26 and 27 is used). Thus, the use of the universalclamp subassembly of FIGS. 26 and 27 advantageously reduces the partcount of the PV module mounting system, as compared to installationsrequiring separate mid-clamps and end clamps. As best shown in thesectional view of FIG. 27, the cantilevered portion of the upper plateportion 234 of the L-shaped clamp member 226 comprises one or moreprotrusions 237 that are designed to penetrate the non-conductive,anodized layers of the PV module 102 so as to provide a ground currentpath (or a current path to ground) when the clamp member 226 iscompressed against the PV module 102 by the tightening of the nut 200.In one or more embodiments, the clamp member 226 may comprise aplurality of spaced-apart protrusions 237 along an extending length ofthe cantilevered portion of the upper plate portion 234. Also, in one ormore embodiments, a top surface of the flange base portion 168 of thepivotal base member 158 may be provided with a spacer member (e.g., apiece of foam or other suitable spacer member) disposed approximately inthe middle of the top surface of the flange base portion 168. Similar tothe spacer members with abutments 58, 60 and 64, 66 described above withregard to the embodiment illustrated in FIGS. 3-6, the spacer member onthe top surface of the flange base portion 168 facilitates the propereast-west positioning of adjacent PV modules 102 in a row when the clampassembly of FIGS. 26 and 27 is used as a mid-clamp connecting twoadjacent PV modules 102.

A third type of clamp subassembly (or clamp assembly) used as PV moduleattachment means of the support assembly 112 is illustrated in FIGS.28-30. Initially, as shown in the exploded view of FIG. 28, the thirdtype of clamp subassembly generally comprises a pivotal base member158′, an upper clamp member 176 coupled to the pivotal base member 158′by a fastener (e.g., headless-type assembly bolt 198 with correspondingnut 200), and a bonding clamp member 186 coupled to the upper clampmember 176 and the pivotal base member 158′ by the fastener (e.g., 198,200), wherein a portion of the bonding clamp member 186 is configured tobe disposed between two PV modules 102 (refer to the sectional views ofFIGS. 29 and 33). Referring again to FIG. 28, it can be seen that thepivotal base member 158′ further includes a base portion 160′ with acurved bottom surface 162′, and an L-shaped flange portion 166′ with aflange base portion 168′ and an upright portion 172′. The base portion160′ of the pivotal base member 158′ comprises a generally downwardlyextending protrusion 164 transversely disposed thereacross, and anaperture 165 disposed through the curved bottom surface 162′ thereof.The flange base portion 168′ of the L-shaped flange portion 166′comprises a fastener aperture 170′ for accommodating a fastener (e.g.,headless-type assembly bolt or stud 198). In the illustrated embodiment,the fastener aperture 170′ is provided with a plurality of internalthreads for matingly engaging with the external threads on the bolt 198.In another embodiment, the end of the bolt 198 can be embedded in theflange planar base portion 168′. Advantageously, the centrally disposedbolt 198 extending from the planar base portion 168′ is configured todefine a clearance gap between adjacent PV modules 102 mounted to theclamp subassembly (i.e., the bolt 198 is used to create a predeterminedspacing between the PV modules 102). The upright portion 172′ of theL-shaped flange portion 166′ also comprises a fastener aperture 174′ foraccommodating a fastener (e.g., headless-type bolt or stud 202 withcorresponding nut 204, which can be used for securing the top edgeportion of the wind deflector 222 to the support assembly 112). Similarto the fastener aperture 170′, the fastener aperture 174′ of theillustrated embodiment is provided with a plurality of internal threadsfor matingly engaging with the external threads on the bolt 202. Inanother embodiment, the end of the bolt 202 can be embedded in theupright portion 172′.

Still referring to FIG. 28, it can be seen that the upper clamp member176 generally comprises a plate portion 178 with a fastener aperture 180disposed therethrough for accommodating a fastener (e.g., headless-typeassembly bolt 198 with corresponding nut 200). The upper clamp member176 further comprises spaced apart protrusions 182 (see FIG. 29)extending from a lower surface thereof, wherein a gap 184 is formedbetween the spaced apart protrusions 182 of the upper clamp member 176,and wherein the spaced apart protrusions 182 are configured to preventthe one or more PV modules 102 from becoming disengaged from the upperclamp member 176, and the gap 184 between the spaced apart protrusions182 is configured to accommodate thermal expansion and contraction ofthe one or more photovoltaic modules 102. As shown in FIGS. 29 and 33,the spaced apart protrusions 182 are disposed on opposite sides of PVmodule flanges when the upper clamp member 176 is tightened against thetop surface of the PV modules 102 (e.g., by torqueing nut 200). Thus,the upper clamp member 176 is in the form of a compression clamp (i.e.,it is compressed against the top surfaces of the PV modules 102 by thetightening of the nut 200). In some embodiments, the flange baseportions 168, 168′ may include spaced apart protrusions, similar to thespaced apart protrusions 182 of the upper clamp member 176.

In one or more embodiments, the upper clamp member 176 and the bondingclamp member 186 of the third clamp subassembly each comprises aconductive material so as to provide integrated grounding for the one ormore PV modules 102. For example, the upper clamp member 176 and thebonding clamp member 186 may individually, together, or in cooperationwith other components of the support assembly 112, form a groundingcurrent path between adjacent PV modules 102. In particular, the upperclamp member 176 may be formed of stainless steel for strength and to beconductive with the bonding clamp member 186. As explained above, thespaced apart protrusions 182 disposed on the lower/outer edges preventthe PV modules 102 from sliding out and becoming unattached from theupper clamp member 176 of the support assembly 112. The gap 184 betweenthe spaced apart protrusions 182 allows for thermal movements. While theillustrated bonding clamp member 186 comprises one form of a bondingmethod that may be practiced in accordance with the principles of theinvention, it is to be understood that other components of the supportassembly 112 may provide integrated grounding for the PV modules 102 aswell, such as other components of the clamp subassemblies (e.g., in someembodiments, all components of the clamp subassemblies may be conductivefor grounding purposes). Advantageously, the support assembly 112described herein comprises one or more components, such as the pivotalbase member 158, 158′, the upper clamp members 176, 176′, the bondingclamp member 186, and the L-shaped side clamp member 226, thatintegrates grounding from one PV module 102 to the next. The upper clampmember 176 and the bonding clamp member 186 are exemplary types ofsuitable compression grounds that may be utilized in the supportassemblies 112 described herein. When the upper clamp member 176 iscompressed by the tightening of the nut 200, the protrusions (or spikes)182 on the upper clamp member 176 are designed to penetrate thenon-conductive, anodized layers of the PV modules 102 so as to provide aground current path (or a current path to ground).

With reference to FIGS. 28 and 29, it can be seen that the bonding clampmember 186 of the third clamp subassembly generally comprises a bottomwall 192, opposed tapered side walls 190 connected to the bottom wall192, and opposed flange portions 188 connected to the upper ends of thetapered side walls 190. The bottom wall 192 of the bonding clamp member186 comprises a fastener aperture 194 disposed therethrough foraccommodating a fastener (e.g., headless-type assembly bolt 198 withcorresponding nut 200). Advantageously, the bonding clamp member 186 hasa structural configuration and a material composition that enables thebonding clamp member 186 to accommodate thermal expansion andcontraction of one or more PV modules 102. In particular, the bondingclamp member 186 only has protrusions downward into each PV module 102,whereas the top is smooth. This allows for thermal expansion andcontraction. The sliding of the bonding clamp member 186 is possiblebecause the upper clamp member 176 is preferably made of stainlesssteel, and not aluminum which requires the piercing of the anodizationlayer of the PV module 102. Aluminum has a non-conductive layer, whilesteel is very conductive.

Also, as best shown in the sectional views of FIGS. 29 and 33, thebottom wall 192 and opposed side wall portions 190 of the bonding clampmember 186 are configured to drop down between the side flanges 106 ofadjacent PV modules 102 so as to provide integrated grounding for the PVmodules 102 (i.e., the metallic, electrically conductive bonding clampmember 186 helps to establish a current path between PV modules 102 sothat conventional grounding, such as a network of copper wire, is notrequired). Thus, the bonding clamp member 186 reduces material andinstallation costs associated with the installation of a photovoltaicsystem or array 100.

In one alternative embodiment, rather than using the headless-typeassembly bolt 198 with corresponding nut 200 in the clamp subassembliesdescribed above, a serrated flange hex bolt may be used to hold thecomponents of the clamp assemblies together. Advantageously, theserrated flange hex bolt has a simple configuration and locks intoplace. Preferably, both the headless-type assembly bolt 198 describedabove, and the alternative serrated flange hex bolt would be made of aconductive material so as to provide conductivity between the upperclamp members 176, 176′ and the pivotal base member 158, 158′.

Advantageously, the pivotal base members 158, 158′ of the clampsubassemblies described above swivel or rotate in the concave notches orpockets 130, 144 of the upright support members 120, 134 of the supportassembly 112 so as to accommodate a plurality of different tilt anglesof one or more PV modules 102, as determined by the sizes of the PVmodules 102 and orientation that they are installed (e.g., accommodatingPV module tilt angles ranging from approximately four (4) degrees toapproximately twelve (12) degrees, inclusive; or ranging between four(4) degrees and twelve (12) degrees, inclusive). During the installationprocess, the pivotal base members 158, 158′ of the clamp subassembliesare simply rotated about their respective clevis pins 196 until thedesired PV module tilt angle is achieved.

In addition, the clamp subassemblies described above are preferablydetachably coupled to the first upright support member 120 and/or thesecond upright support member 134 by a removable pin member (e.g., aremovable clevis pin 196) such that the upright portion 172, 172′ of theL-shaped flange portions 166, 166′ are capable of being disposed near aselected one of opposite sides of one of the first upright supportmember 120 and the second upright support member 134 (e.g., near eitherfront wall 122 or rear wall 126 of first upright support member 120; ornear either front wall 136 or rear wall 140 of second upright supportmember 134). Advantageously, the removable nature of the clampsubassemblies allows selected ones of the support assemblies 112 a to beinstalled “backwards” on the north row of the PV system or array 100(refer to FIG. 31, the direction of the northernmost support assemblies112 a are flipped relative to the other support assemblies 112). Thispermits the northernmost support assemblies 112 a to be tucked under thePV modules 102 in the north row to reduce the footprint of the PV array100, and to enable more PV modules 102 to fit on a rooftop, while alsodecreasing the wind drag of the system 100.

In one or more embodiments, all of the clamping components (e.g.,pivotal base members 158, 158′, upper clamp members 176, 176′, bondingclamp member 186, bolt 198, nut 200, L-shaped side clamp member 226)described in conjunction with first, second, and third clampsubassemblies are formed from metal so as to enable the clamp componentsto be both electrically conductive and structurally rigid.

Now, other illustrated features of the base portion 116 of the supportassembly 112 will be described. Initially, with reference to FIGS. 17,18, and 20-22, it can be seen that the base portion 116 comprisesintegral wire clips 148 for accommodating one or more wires of one ormore photovoltaic (PV) modules 102. Advantageously, the wire clips 148are integrally formed in the base portion 116 (e.g., integrally moldedinto the plastic of the base portion 116). The integral wire clips 148are particularly designed for accommodating PV module wires that arerunning in the north/south direction. As shown in FIGS. 17 and 18, thewire clips 148 are longitudinally spaced apart along the length of thebase portion 116 (i.e., from front-to-back). Also, as illustrated inthese figures, successive wire clips 148 are arranged in oppositedirections (i.e., the wire clips 148 open in opposite directions) so asto securely hold the PV module wires in place. Each wire clip 148 oneach side of the base portion 116 is designed to hold two (2) PV modulewires, which is enough for connecting PV source circuits.Advantageously, the integral wire clips 148 obviate the need forseparate wire clips, thereby reducing both part and labor costs for a PVarray installation.

As depicted in FIGS. 18, 20, and 22, the illustrated first uprightsupport member 120 comprises an integrally formed slot 150 in the frontwall 122 thereof for receiving an edge of a wind deflector or windshield (e.g., wind deflector 222 in FIG. 23). Similarly, the opposite,rear wall 126 of the first upright support member 120 also comprises anintegrally formed slot 152 formed therein for receiving an edge of awind deflector (e.g., wind deflector 222). Advantageously, theintegrally formed slots 150, 152 enable the bottom edge of a winddeflector 222 to be coupled to the support assembly 112 without afastener. Because a fastener is only needed at the top of the winddeflector 222, and not at the bottom thereof, the integrally formedslots 150, 152 of the support assembly 112 reduce the requisite numberof wind deflector securement fasteners in half, thereby saving materialcosts and installation labor. Additional details of the wind deflectorconfiguration will be discussed hereinafter.

In addition, with reference to FIGS. 17, 19, and 32, the illustratedbase portion 116 of the support assembly 112 comprises a bottom surfacewith one or more grooves 216 (see FIGS. 19 and 32) for accommodating oneor more respective gaskets or pieces of cord stock 218 (see FIG. 32). Inone embodiment, the cord stock may comprise ethylene-propylene-dienemonomer (EDPM) cord stock (i.e., EDPM O-rings). Advantageously, the useof the gaskets or pieces of cord stock 218 in the grooves 216 of thebase portion 116 increases the grip of the support assembly 112 on therooftop support surface 108, and it protects the membrane of the rooftopsupport surface 108 from potential tears. As such, the bottom of thebase portion 116 of the support assembly 112 is roof-friendly because itis designed to prevent the roof membrane from being damaged orpunctured. In order to further protect the integrity of the roofingmembrane, it can be seen in FIGS. 19 and 32 that the bottom of the baseportion 116 of the support assembly 112 is generally provided with allrounded surfaces at corners so as to ensure that there are no sharpedges or corners that could tear the roof. The gaskets or pieces of cordstock 218 are low cost and can be installed at the factory, therebyobviating the need for the on-site installation thereof. Also,advantageously the friction fit of the gaskets or pieces of cord stock218 against the rooftop support surface 108 allows the support assembly112 to be easily removed at the end of its life cycle for recyclingpurposes.

Referring to FIGS. 17-19, it can be seen that the illustrated baseportion 116 of the support assembly 112 is provided with a plurality ofdrainage channels 212 and a plurality of weep holes 214 for drainingwater from the base portion 116. Thus, rain water and other meltingprecipitation will not collect in the tray-like base portion 116 of thesupport assembly 112 (i.e., the precipitation will not excessively poolin the recessed portion 118 of the base portion 116). As shown in FIGS.17 and 18, the drainage channels 212 are generally connected todiagonally opposite corners of each generally square-shaped weep hole214. However, it is to be understood that other suitable geometries maybe used for the weep holes 214 (e.g., circular) and other suitableconfigurations can be used for the drainage channels 212.

In addition, as shown in the end views of FIGS. 20 and 21, theillustrated base portion 116 of the support assembly 112 comprises aplurality of spaced-apart raised profile portions 217 on the bottomsurface thereof so as to allow for drainage underneath the base portion116. The raised profile portions 217 elevate a portion of the bottomsurface of the base portion 116 of the support assembly 112 above thesupport surface (e.g., the roof) so that water is capable of drainingbetween the raised profile portions 217, thereby preventing water frombecoming trapped underneath the base portion 116.

As shown in the front and rear views of FIGS. 20 and 21, many of thefeatures of the base portion 116 of the support assembly 112 describedabove are symmetrically arranged with respect to a centerline C1disposed in the middle of a transverse profile of the support assembly112. For example, the wire clips 148 illustrated in FIGS. 20 and 21 aresymmetrically arranged with respect to the centerline C1.

While the support assemblies 112 are generally not required to beattached to the rooftop support surface 108 in most installations,nonetheless, the base portion 116 of the illustrated support assembly112 is provided with a plurality of attachment points 210 (e.g., in theform of square-shaped apertures disposed therethrough—see FIGS. 17-19)for accommodating high wind or seismic installation areas, or foraccommodating wireways. In such installations, a lag bolt can beinserted from the bottom, and through one of the attachment points 210.Advantageously, the large bearing surface of the lag bolt is used toprevent spinning while torqueing. An L-shaped bracket, which is commonlyused in PV installations, can be tightened onto the top of the part.Custom brackets may also be used.

Similar to that described in conjunction with the third embodimentabove, the fourth embodiment also includes rear wind shields or winddeflectors 222 supported by the support assemblies 112 at the rear sideof the illustrated PV module rows in order to reduce wind load (seee.g., FIGS. 14, 15, 24, and 31). The illustrated wind deflectors 222 areheld by the first upright support members 120 of the support assemblies112 and are shaped to deflect wind, blowing from the north, up and overthe array of PV modules 102 rather than under the PV modules 102 inorder to reduce wind load. Referring to the assembled view of FIG. 15and the exploded view of FIG. 23, it can be seen that the illustratedupper flange of the wind deflector 222 is provided with a plurality ofelongated apertures or slots 224 for receiving fasteners (e.g.,headless-type bolts 202 described above) which secure the upper flange(upper edge portion) of the wind deflector 222 to the support assemblies112. The elongated apertures or slots 224 in the upper flange (upperedge portion) of the wind deflector 222 accommodate various PV module orpanel widths 102 and accommodate for thermal expansion and contractionof the wind deflector 222. In addition, the elongated apertures or slots224 in the upper edge portion of the wind deflector 222 also allow forthe thermal expansion and contraction of the PV modules 102.Advantageously, as described above, the lower flange (lower edgeportion) of the wind deflector 222 is not required to contain anyapertures for its securement to the support assemblies 112 because thelower flange (lower edge portion) of the wind deflector 222 merely slipsinto the wind deflector slot 152 in the rear wall 126 of the firstupright support member 120, or alternatively, into the wind deflectorslot 150 in the front wall 122 of the first upright support member 120.While the wind deflector 222 is not required in all installations of thePV system 100, it is beneficial for reducing the wind forces exerted onthe PV modules 102 and it allows the PV system 100 to be installed inmore severe wind areas. Further, as shown in FIG. 14, the winddeflectors 222 of the array are capable of being overlapped so as toadditionally accommodate for PV modules 102 with different dimensions(i.e., the overlapped portions 244 of the wind deflectors 222 in FIG. 14are able to accommodate PV modules 102 having different widths).

As best shown in FIG. 23, the wind deflectors 222 have a cross-sectionalprofile that allows the wind deflectors 222 to be nested together in astacked arrangement during shipping to lower shipping and handlingcosts. That is, because the shipping size of the wind deflectors 222 isminimized by their stacked arrangement, the shipping and handling costsassociated with transporting the wind deflectors 222 is able to belowered.

Further, as illustrated in FIG. 23, the wind deflector 222 alsocomprises a small circular aperture 246 for securing a grounding lug ofthe photovoltaic array to the body portion of the wind deflector 222. Asshown in this figure, in the illustrative embodiment, the grounding lugaperture 246 is disposed in the lower flange (lower edge portion) of thewind deflector 222.

FIGS. 34, 36, 46, 49-52, 54, 56, and 57 illustrate a photovoltaic systemor array 400 according to another exemplary embodiment of the presentinvention. As shown in these figures, the illustrated photovoltaicsystem or array 400 includes an array of solar panels or PV modules 310that are configured to be supported on a substantially flat supportsurface (e.g., a building rooftop) by a mounting system. In thesefigures, there are two rows of PV modules 310 illustrated for exemplarypurposes, each of the two rows having two (2) PV modules 310 disposedtherein. The illustrated mounting system includes a plurality of supportassemblies 312 that rest on the support surface and support and orientthe PV modules 310 above the support surface and a plurality of ballasts314 in the form of ballast blocks that weight the array 400 to thesupport surface to maintain the position of the array 400 on the supportsurface. As shown in FIGS. 34 and 50, the three (3) support assemblies312 disposed in the middle of the PV array 400 bridge the two rows of PVmodules 310. The PV array 400 illustrated in FIGS. 34, 36, 46, 49-52,54, 56, and 57 has each of the rectangular shaped PV modules 310oriented in a landscape orientation, that is, with the longest axis ofthe PV modules 310 extending in a lateral or side-to-side directionwhich is typically the east-west direction. In the exemplary embodiment,the illustrated PV modules 310 are supported in an inclined positionsuch that the forward end of each PV module 310 is positioned lower thanits rearward end so that typically the southern end is positioned lowerthan the northern end.

As shown in the perspective views of FIGS. 34 and 49, each illustratedPV module 310 is supported by a plurality of the support assemblies 312.At least three of the support assemblies 312 must be utilized for eachof the PV modules 310 in order to establish a desired plane for the PVmodules 310. For the illustrated rectangular-shaped PV modules 310, atleast four of the support assemblies 312 are preferably utilized tosupport each of the PV modules 310 so that they can be positioned at ornear each corner of the rectangular-shaped PV modules 310. Each supportassembly 312 supports at least one of the PV modules 310 but some of theillustrated support assemblies 312 support more than one of the PVmodules 310. As will be described in more detail hereinafter, theillustrated PV modules 310 are secured to the support assemblies 312 byclamp subassemblies 354, 356 (see e.g., FIG. 37). Securing the supportassemblies 312 at or near the corners of PV modules 310 allows themounting system to be used with PV modules 310 of any width and lengthwithout requiring customization or modification to the supportassemblies 312 or the PV modules 310. Thus, a common support assembly312 can be used in many applications to mount many different models ofPV modules 310. Also, the illustrated support assemblies 312 are notfastened to the support surface and simply rest on the support surfaceas they are weighted in place by the ballasts 314. Therefore, thesupport assemblies 312 do not penetrate the roof membrane of the supportsurface, nor do they require fasteners that penetrate the roof membraneof the support surface. That is, the support assembly 312 is in the formof a non-penetrating support device that does not penetrate the supportsurface.

With the exception of the clamping assembly components, the supportassembly 312 can be formed entirely of polymer or plastic. That is, thebody portion of the support assembly 312 (see FIGS. 40-44), whichincludes the base portion 316, the first upright support member 320, andthe second upright support member 334 can be formed entirely of polymeror plastic, and components 316, 320, 334 can all be molded as anintegral unit from a polymer or plastic. One suitable polymer or plasticfor the body of the support assembly 312 is acrylonitrile styreneacrylate (ASA) Luran® by Styrolution. The use of a highly durableplastic, such as Luran®, ensures that the support assembly 312 will beable to withstand the toughest rooftop exposure for twenty-five (25)years or more (i.e., the support assembly 312 has substantialweatherability). Advantageously, plastic is harmless on the roofmembrane, it is non-corrosive, it is non-conductive (i.e., it does notpose any electrical potential threat), and it has a low cost.

Now, with particular reference to FIGS. 38-44, the structural featuresof the illustrated support assembly 312 will be described in detail. Asbest shown in the perspective views of FIGS. 40 and 41, the supportassembly 312 generally comprises a base portion 316, the base portion316 including a recessed portion 318; a first upright support member 320coupled to the base portion 316, the first upright support member 320having a top surface 328, the top surface 328 being disposed at a firstelevation E3 relative to the base portion 316 of the support assembly312 (i.e., relative to the bottom surface of the base portion 316—seeFIG. 44); and a second upright support member 334 coupled to the baseportion 316, the second upright support member 334 spaced apart from thefirst upright support member 320 across the recessed portion 318 of thebase portion 316, the second upright support member 334 having a topsurface 342, the top surface 342 being disposed at a second elevation E4relative to the base portion 316 of the support assembly 312 (i.e.,relative to the bottom surface of the base portion 316—see FIG. 44). Asshown in the side view of FIG. 44, the first elevation E3 of the topsurface 328 is higher than the second elevation E4 of the top surface342. Also, as illustrated in FIGS. 40 and 41, each of the first andsecond upright support members 320, 334 is provided with a respectiveperipheral recess 332, 346 therearound.

As shown in the top perspective views of FIGS. 38 and 40, the baseportion 316 of the support assembly 312 is provided with a downturnedperipheral edge 402 around the periphery thereof. The downturnedperipheral edge 402 of the base portion 316 circumscribes the recessedportion 318 of the support assembly, as well as the first and secondupright support members 320, 334. Now, turning to the bottom perspectiveview of FIG. 41, it can be seen that the four (4) sides of thedownturned peripheral edge 402 are provided with a plurality ofspaced-apart reinforcement ribs 408 disposed under the downturnedperipheral edge 402. The reinforcement ribs 408 structurally support thesides of the downturned peripheral edge 402, and more generally, addstructural rigidity to the support assembly 312 as a whole.

Advantageously, the generally hollow shape and large draft angles of theplastic body portion of the support assemblies 312 (i.e., the plasticbody portion comprising the base portion 316, the first upright supportmember 320, and the second upright support member 334) allow for theillustrated support assemblies 312 to be nested together when stacked tolower shipping and handling costs.

With continued reference to FIGS. 38-44, it can be seen that the firstupright support member 320 comprises a front wall 322, opposed sidewalls 324, and a rear wall 326. Each of these walls 322, 324, 326 issloped inwardly in an upward direction such that the first uprightsupport member 320 has a generally truncated pyramidal shape. Similarly,the second upright support member 334 comprises a front wall 336,opposed side walls 338, and a rear wall 340. Like the walls 322, 324,326 of the first upright support member 320, the walls 336, 338, 340 ofthe second upright support member 334 are also sloped inwardly in anupward direction so as to also give the second upright support member334 a generally truncated pyramidal shape. However, as shown mostclearly in FIGS. 38 and 40, the pyramidal second upright support member334 has a smaller footprint and height than the pyramidal first uprightsupport member 320. While the illustrated first and second uprightsupport members 320, 334 generally have truncated pyramidal shapes, itis to be understood that other suitable shapes may be used for the firstand second upright support members 320, 334 such as, for example, arectangular shape (i.e., alternative upright support members could havea post-like appearance). In an exemplary embodiment, the supportassembly 312 has a footprint of approximately 16.5 inches long by 6.5inches wide, and has a tapered base from the front to the rear in orderto reduce the amount of material required to form the base.

As best illustrated in FIG. 40, the first and second upright supportmembers 320, 334 are provided with respective concave notches or pockets330, 344 for receiving respective base portions of respective rotatableclamp subassemblies 354, 356. As shown in the bottom perspective view ofFIG. 41, the underside of each of the concave notches or pockets 330,344 is provided with a plurality of spaced-apart reinforcement ribs 410in order to strengthen the portion of the upright support members 320,334 bearing the weight of the rotatable clamp subassemblies 354, 356.Referring to the assembled view of FIG. 38, it can be seen that theillustrated support assembly 312 comprises a first rotatable clampsubassembly 354 rotatably coupled to the first upright support member320 via a clevis pin 396, which is received within a clevis pin aperture329 (see FIGS. 40 and 44). The first rotatable clamp subassembly 354 isconfigured to be coupled to one or more photovoltaic modules 310 (e.g.,to the north side of one or more photovoltaic modules 310, asillustrated in FIG. 34). Similarly, the second rotatable clampsubassembly 356 is rotatably coupled to the second upright supportmember 334 via a clevis pin 396, which is received within a clevis pinaperture 343 (see FIGS. 40 and 44). The second rotatable clampsubassembly 356 is configured to be coupled to one or more otherphotovoltaic modules 310 (e.g., to the south side of one or morephotovoltaic modules 310, as illustrated in FIG. 34). In one embodiment,the clevis pins 396 are in the form of self-locking implanted cotter pin(SLIC) type clevis pins that snap into place without the need for acotter pin or other secondary retention part. Advantageously, byeliminating the use of a cotter pin, the SLIC clevis pin (or SLIC pin)saves installation time and money. Although, it is to be understood thatother suitable fasteners may also be used to attach the first and secondrotatable clamp subassemblies 354, 356 to their respective first andsecond upright support members 320 and 334.

An exemplary clamp subassembly (or clamp assembly) used as the PV moduleattachment means of the support assembly 312 is illustrated in FIGS. 47and 48. As shown in the exploded view of FIG. 47, the exemplary clampsubassembly generally comprises a pivotal base member 358 and anL-shaped side clamp member 384, wherein the L-shaped side clamp member384 is coupled to the pivotal base member 358 by a fastener (e.g.,headless-type assembly bolt 376 with corresponding nut 378). Referringagain to FIG. 47, it can be seen that the pivotal base member 358further includes a base portion 360 with a curved bottom surface 362,and an L-shaped flange portion 366 with a flange base portion 368 and anupright portion 372. The flange base portion 368 comprises an elevatedshelf portion with a fastener aperture 370 for accommodating a fastener(e.g., headless-type assembly bolt or stud 376). In the illustratedembodiment, the fastener aperture 370 is provided with a plurality ofinternal threads for matingly engaging with the external threads on thebolt 376. In another embodiment, the end of the bolt 376 can be embeddedin the flange base portion 368. A ring washer 398 may be provided on thebolt 376 in order to hold open the clamp subassembly by elevating theL-shaped side clamp member 384 a predetermined distance above the flangebase portion 368 so that the photovoltaic modules 310 may be more easilyinserted into the clamp subassembly. Referring again to FIG. 47, it canbe seen that the upright portion 372 of the L-shaped flange portion 366of the pivotal base member 358 also comprises a fastener aperture 374for accommodating a fastener (e.g., headless-type bolt or stud 380 withcorresponding nut 382, which can be used for securing the top edgeportion of the wind deflector 422 to the support assembly 312—see FIGS.35 and 45). Similar to the fastener aperture 370, the fastener aperture374 of the illustrated embodiment is provided with a plurality ofinternal threads for matingly engaging with the external threads on thebolt 380. In another embodiment, the end of the bolt 380 can be embeddedin the upright portion 372.

With combined reference to FIGS. 47 and 48, it can be seen that the baseportion 368 of the clamp pivotal base member 358 further includes adownwardly sloped flange portion 369 configured to facilitate aninsertion of the PV modules 310 into the clamp subassembly. As shown inFIG. 48, the downwardly sloped flange portion 369 of the clamp pivotalbase member 358 is angled downwardly towards a top surface of theupright support member 320 of the base portion 316 of the supportassembly 312. In addition to facilitating an insertion of the PV modules310 into the clamp subassembly, the downwardly sloped flange portion 369also limits a rotation of the clamp subassembly on the upright supportmember 320 of the base portion 316 (i.e., when the bottom edge of thedownwardly sloped flange portion 369 contacts the top surface of thesupport member 320). This rotational limit imposed by the downwardlysloped flange portion 369 also facilitates the ease of installation ofthe PV modules 310.

In addition, referring again to FIGS. 47 and 48, it can be seen that theelevated shelf portion of the base portion 368 of the clamp pivotal basemember 358 comprises a cantilevered edge 371 where it meets the sideflange 365 of the PV module frame (see FIG. 48). Advantageously, therecess 373 underneath the cantilevered edge 371 (refer to FIGS. 47 and48) enables the clamp subassembly to be coupled with another accessoryof the photovoltaic array.

With continued reference to FIG. 47, it can be seen that the L-shapedside clamp member 384 generally comprises a bottom wall 386, opposedside walls 388 connected to the bottom wall 386, and an upper plateportion 390 connected to the upper ends of the opposed side walls 388.The bottom wall 386 of the L-shaped side clamp member 384 comprises afastener aperture disposed therethrough (not visible in FIG. 47) foraccommodating a fastener (e.g., headless-type assembly bolt 376 withcorresponding nut 378). The upper plate portion 390 of the L-shaped sideclamp member 384 comprises a fastener aperture 394 disposedtherethrough, which is generally axially aligned with the fasteneraperture in the bottom wall 386, for accommodating a fastener (e.g.,headless-type assembly bolt 376 with corresponding nut 378). As shown inFIG. 47, the upper plate portion 390 of the L-shaped side clamp member384 also includes a chamfered edge 392.

Next, referring primarily to the sectional view of FIG. 48, the mannerin which the clamp subassembly engages one or more PV modules 310 willbe described. In this figure, it can be seen that, when the L-shapedside clamp member 384 is tightened against the upper surface of the PVmodule 310 (e.g., by torqueing nut 378), the bottom flange 364 of the PVmodule 310 abuts the upper surface of base portion 360 of the pivotalbase member 358, and the side flange 365 of the PV module 310 abuts theinner side wall 388 of the L-shaped side clamp member 384. As such, theone or more PV modules 310 are clamped into place on the supportassembly 312.

Advantageously, the clamp subassembly illustrated in FIGS. 47 and 48 iscapable of being used as a universal-type clamp that can be attachedanywhere along a side of a PV module 310. As such, when the clampsubassembly of FIGS. 47 and 48 is used, there is no need for twodifferent types of clamps in the PV module installation (i.e., aseparate mid-clamp and end clamp are not required when the clampsubassembly of FIGS. 47 and 48 is used). Thus, the use of the universalclamp subassembly of FIGS. 47 and 48 advantageously reduces the partcount of the PV module mounting system, as compared to installationsrequiring separate mid-clamps and end clamps. As best shown in thesectional view of FIG. 48, the underside of the cantilevered portion ofthe upper plate portion 390 of the L-shaped clamp member 384 may beserrated in order to penetrate the non-conductive, anodized layers ofthe PV module 310 so as to provide a ground current path (or a currentpath to ground) when the clamp member 384 is compressed against the PVmodule 310 by the tightening of the nut 378. Also, in one or moreembodiments, a top surface of the flange base portion 368 of the pivotalbase member 358 may be provided with a spacer member (e.g., a piece offoam or other suitable spacer member) disposed approximately in themiddle of the top surface of the flange base portion 368 so as tofacilitate the proper east-west positioning of adjacent PV modules 310in a row when the clamp assembly of FIGS. 47 and 48 is used as amid-clamp connecting two adjacent PV modules 310.

Advantageously, the pivotal base member 358 of the clamp subassemblydescribed above swivels or rotates in the concave notches or pockets330, 344 of the upright support members 320, 334 of the support assembly312 so as to accommodate the tilt angle adjustment of the PV modules310. In the illustrative embodiment, the PV modules 310 are configuredto be disposed at a tilt angle of approximately five (5) degreesrelative to the support surface on which they are disposed (e.g.,relative to the building roof). During the installation process, thepivotal base members 358 of the clamp subassemblies are simply rotatedabout their respective clevis pins 396 until the desired PV module tiltangle is achieved.

In addition, the clamp subassemblies described above are preferablydetachably coupled to the first upright support member 320 and/or thesecond upright support member 334 by a removable pin member (e.g., aremovable clevis pin 396) such that the upright portion 372 of theL-shaped flange portions 366 are capable of being disposed near aselected one of opposite sides of one of the first upright supportmember 320 and the second upright support member 334 (e.g., near eitherfront wall 322 or rear wall 326 of first upright support member 320, ornear either front wall 336 or rear wall 340 of second upright supportmember 334).

In one or more embodiments, all of the clamping components (e.g.,pivotal base members 358, bolt 376, nut 378, and the L-shaped side clampmember 384) described above in conjunction with clamp subassembly areformed from metal so as to enable the clamp components to be bothelectrically conductive and structurally rigid.

Now, other illustrated features of the base portion 316 of the supportassembly 312 will be described. Initially, with reference to FIGS. 38-40and 61-63, it can be seen that the base portion 316 of the supportassembly 312 comprises a plurality of spaced-apart wire clip slots 348integrally formed in the top portion of the downturned peripheral edge402. As shown in FIGS. 61-63, each of the wire clip slots 348 receives arespective downwardly extending tab portion of a wire clip 416 therein.The wire clips 416 accommodate the wires of the photovoltaic (PV)modules 310 in the array 400. In particular, the wire clips 416 areparticularly designed for accommodating PV module wires that are runningin the north/south direction. As shown in FIG. 61, the wire clips 416are longitudinally spaced apart along the length of the base portion 316(i.e., from front-to-back). Also, as illustrated in this figure,successive wire clips 416 may be arranged in opposite directions withinthe wire clip slots 348 (i.e., the wire clips 416 may be arranged toopen in opposite directions) so as to securely hold the PV module wiresin place. Each wire clip 416 may hold at least two (2) PV module wires,which is enough for connecting PV source circuits.

As depicted in FIGS. 38, 40, and 44, the illustrated first uprightsupport member 320 comprises an integrally formed wind deflector slot350 in the front wall 322 thereof for receiving an edge of a winddeflector or wind shield (e.g., wind deflector 422 in FIG. 45).Similarly, the opposite, rear wall 326 of the first upright supportmember 320 also comprises an integrally formed wind deflector slot 352formed therein for receiving an edge of a wind deflector (e.g., winddeflector 422). Advantageously, the integrally formed wind deflectorslots 350, 352 enable the bottom edge of a wind deflector 422 to becoupled to the support assembly 312 without a fastener. Because afastener is only needed at the top of the wind deflector 422, and not atthe bottom thereof, the integrally formed wind deflector slots 350, 352of the support assembly 312 reduce the requisite number of winddeflector securement fasteners in half, thereby saving material costsand installation labor. Additional details of the wind deflectorconfiguration will be discussed hereinafter.

In addition, as shown in FIGS. 37, 44, and 55, the illustrated firstupright support member 320 comprises an integrally formed ballast trayslot 412 in the rear wall 326 thereof for receiving a first upturnededge 420 of a ballast tray 418 (see FIG. 55). Similarly, the illustratedsecond upright support member 334 comprises an integrally formed ballasttray slot 414 in the front wall 336 thereof for receiving a secondupturned edge 420 of the ballast tray 418 (see FIG. 37). Advantageously,the integrally formed slots 412, 414 enable the first and secondupturned edges 420 of the ballast tray 418 to be coupled to the supportassemblies 312 without fasteners. In FIG. 38, it can be seen that anaperture 413 is provided in the rear wall 326 of the first uprightsupport member 320 beneath the ballast tray slot 412. Similarly as shownin FIG. 40, an aperture 415 is provided in the front wall 336 of thesecond upright support member 334 beneath the ballast tray slot 414.

In addition, with reference to the bottom perspective view of FIG. 41,the illustrated base portion 316 of the support assembly 312 comprises abottom surface with a plurality of integrally formed foot members 406molded therein (e.g., a pair of spaced-apart foot members 406)configured to rest on the support surface (e.g., the building roof).Advantageously, the foot members 406 of the base portion 316 increasesthe grip of the support assembly 312 on the rooftop support surface.Also, the bottom of the base portion 316 of the support assembly 312 isroof-friendly because it is designed to prevent the roof membrane frombeing damaged or punctured. In order to further protect the integrity ofthe roofing membrane, it can be seen in FIG. 41 that the bottom of thebase portion 316 of the support assembly 312 is generally provided withall rounded surfaces at corners so as to ensure that there are no sharpedges or corners that could tear the roof.

Referring to FIGS. 38 and 39, it can be seen that the illustrated baseportion 316 of the support assembly 312 is provided with a plurality ofdrainage channels and a plurality of weep holes 404 for draining waterfrom the base portion 316. Thus, rain water and other meltingprecipitation will not collect in the tray-like base portion 316 of thesupport assembly 312 (i.e., the precipitation will not excessively poolin the recessed portion 318 of the base portion 316). As shown in FIGS.38 and 39, the drainage channels are generally connected to the opposedsides of each generally square-shaped weep hole 404. However, it is tobe understood that other suitable geometries may be used for the weepholes 404 (e.g., circular) and other suitable configurations can be usedfor the drainage channels.

As shown in the front and rear views of FIGS. 42 and 43, many of thefeatures of the base portion 316 of the support assembly 312 describedabove are symmetrically arranged with respect to a centerline C2disposed in the middle of a transverse profile of the support assembly312. For example, the wire clip slots 348 illustrated in FIGS. 38 and 40are symmetrically arranged with respect to the centerline C2.

Next with reference to FIGS. 35, 37, 45, and 55, the ballast tray 418 ofthe photovoltaic module mounting system will be described in furtherdetail. As best shown in the perspective view of FIG. 45, the ballasttray 418 comprises first and second oppositely disposed upturned edges420. As described above, each of the first and second upturned edges 420of the ballast tray 418 is received within a respective one of theballast tray slots 412, 414 of the pair of spaced-apart upright supportmembers 320, 334. As shown in FIGS. 45 and 55, the ballast tray 418comprises a plurality of spaced-apart drainage holes 421 (i.e.,elongated slots 421) for draining water from the ballast tray 418. Insome installations, the drainage holes 421 at the longitudinal ends ofthe ballast tray 418 may also be used for receiving fasteners forsecuring the ballast tray 418 to the support assemblies 312. As shown inFIGS. 34 and 49, the ballast trays 418 are designed to accommodate aplurality of ballasts 314 (e.g., ballasts 314 arranged in an end-to-endconfiguration). In an exemplary embodiment, the ballast blocks 314 havea footprint size of 16″ long by 8″ wide.

Now, referring to FIGS. 52-54 and 56-60, the ballast tray supportbrackets 430 of the mounting system will be described in detail. As bestshown in FIGS. 56 and 57, the ballast tray support brackets 430structurally support the middle portion of the ballast tray 418 betweenthe support assemblies 312 on the support surface (e.g., the buildingrooftop). Advantageously, the ballast tray support brackets 430 preventthe middle portion of the ballast tray 418 from sagging due to theweight of the ballasts 314 and the weight of a person walking across theballasts 314 (e.g., when the person is installing or servicing the PVarray 400). Turning to FIGS. 59 and 60, which illustrate one of theballast tray support brackets 430, it can be seen that the ballast traysupport bracket 430 comprises a first section 432 coupled to a secondsection 444. The first and second sections 432, 444 are adjustablycoupled to one another so that a spanning width of the ballast traysupport bracket 430 is capable of being adjusted so as to accommodatevarying dimensions of photovoltaic module return flanges (i.e.,different projecting lengths of the bottom flange 364 of the PV module310—see FIG. 48). As shown in FIGS. 59 and 60, the first and secondsections 432, 444 of the ballast tray support bracket 430 are adjustablycoupled to one another by means of a fastener member 456 (i.e., ascrew). In the illustrated embodiment, it can be seen that the first andsecond sections 432, 444 of the ballast tray support bracket 430 eachhave a generally L-shaped configuration with a base portion 434, 446attached to an upstanding portion 440, 452 refer to FIGS. 59 and 60).Also, the base portions 434, 446 of the first and second sections 432,444 of the ballast tray support bracket 430 comprise cooperatingelevated parts 436, 448 that elevate the middle portion of the ballasttray 418 above the support surface (e.g., the building rooftop). Moreparticularly, the first L-shaped section 432 of the ballast tray supportbracket 430 has a base portion 434 attached to an upstanding portion 440at an approximately 90 angle, while the second L-shaped section 444 ofthe ballast tray support bracket 430 has a base portion 446 attached toan upstanding portion 452 at an approximately 90 angle. The base portion434 of the first L-shaped section 432 of the ballast tray supportbracket 430 has a stepped elevated part 436, while the base portion 446of the second L-shaped section 444 of the ballast tray support bracket430 has a stepped elevated part 448. As shown in FIG. 60, the steppedelevated part 436 of the base portion 434 of the first L-shaped section432 comprises a plurality of spaced-apart apertures 438 that are alignedwith an elongate slot 450 in the stepped elevated part 448 of the baseportion 446 of the second L-shaped section 444. To facilitate thevariable spanning width of the ballast tray support bracket 430, thefastener member 456 is placed in a selected one of the spaced-apartfastener apertures 438 in the stepped elevated part 436 of the baseportion 434 of the first L-shaped section 432 by the installer. In orderto hold the first and second sections 432, 444 of the ballast traysupport bracket 430 together, the fastener member 456 is secured withinone of the fastener apertures 438 of the first L-shaped section 432 andthe elongate slot 450 of the second L-shaped section 444. In addition,as shown in FIGS. 59 and 60, the upstanding portions 440, 452 of thefirst and second sections 432, 444 of the ballast tray support bracket430 each comprise a respective photovoltaic module frame slot 442, 454formed therein configured to receive an end portion of the photovoltaicmodule return flange (i.e., the photovoltaic module frame slot 442 inthe longer upstanding portion 440 of the first bracket section 432receives the end portion of a photovoltaic module return flange on thehigher north side, while the photovoltaic module frame slot 454 in theshorter upstanding portion 452 of the second bracket section 444receives the end portion of a photovoltaic module return flange on thelow south side.

An alternative embodiment of a ballast tray support bracket 430′ isillustrated in FIGS. 64-69. The ballast tray support bracket 430′ inFIGS. 64-69 is similar in many respects to the ballast tray supportbracket 430 described above, except that the photovoltaic module frameslots 442′, 454′ of the ballast tray support bracket 430′ are configureddifferently than the slots 442, 454 of the aforedescribed ballast traysupport bracket 430. As best shown in FIGS. 66 and 67, similar to theballast tray support bracket 430, the ballast tray support bracket 430′comprises a first section 432′ coupled to a second section 444′. Thefirst and second sections 432′, 444′ are adjustably coupled to oneanother so that a spanning width of the ballast tray support bracket430′ is capable of being adjusted so as to accommodate varyingdimensions of photovoltaic module return flanges (i.e., differentprojecting lengths of the bottom flange 364′ of the PV module—see FIGS.68 and 69). As shown in FIGS. 66 and 67, the first and second sections432′, 444′ of the ballast tray support bracket 430′ are adjustablycoupled to one another by means of a fastener member 456′ (i.e., ascrew). In the illustrated embodiment, it can be seen that the first andsecond sections 432′, 444′ of the ballast tray support bracket 430′ eachhave a generally L-shaped configuration with a base portion 434′, 446′attached to an upstanding portion 440′, 452′ refer to FIGS. 66 and 67).Also, the base portions 434′, 446′ of the first and second sections432′, 444′ of the ballast tray support bracket 430′ comprise cooperatingelevated parts 436′, 448′ that elevate the middle portion of the ballasttray 418 above the support surface (e.g., the building rooftop). Moreparticularly, the first L-shaped section 432′ of the ballast traysupport bracket 430′ has a base portion 434′ attached to an upstandingportion 440′ at an approximately 90 angle, while the second L-shapedsection 444′ of the ballast tray support bracket 430′ has a base portion446′ attached to an upstanding portion 452′ at an approximately 90angle. The base portion 434′ of the first L-shaped section 432′ of theballast tray support bracket 430′ has a stepped elevated part 436′,while the base portion 446′ of the second L-shaped section 444′ of theballast tray support bracket 430′ has a stepped elevated part 448′. Asshown in FIG. 67, the stepped elevated part 436′ of the base portion434′ of the first L-shaped section 432′ comprises a plurality ofspaced-apart apertures 438′ that are aligned with an elongate slot 450′in the stepped elevated part 448′ of the base portion 446′ of the secondL-shaped section 444′. To facilitate the variable spanning width of theballast tray support bracket 430′, the fastener member 456′ is placed ina selected one of the spaced-apart fastener apertures 438′ in thestepped elevated part 436′ of the base portion 434′ of the firstL-shaped section 432′ by the installer. In order to hold the first andsecond sections 432′, 444′ of the ballast tray support bracket 430′together, the fastener member 456′ is secured within one of the fastenerapertures 438′ of the first L-shaped section 432′ and the elongate slot450′ of the second L-shaped section 444′. In addition, as shown in FIGS.66 and 67, the upstanding portions 440′, 452′ of the first and secondsections 432′, 444′ of the ballast tray support bracket 430′ eachcomprise a respective photovoltaic module frame slot 442′, 454′ formedtherein configured to receive an end portion of the photovoltaic modulereturn flange (i.e., the photovoltaic module frame slot 442′ in thelonger upstanding portion 440′ of the first bracket section 432′receives the end portion of a photovoltaic module return flange on thehigher north side, while the photovoltaic module frame slot 454′ in theshorter upstanding portion 452′ of the second bracket section 444′receives the end portion of a photovoltaic module return flange on thelow south side.

The structural features and functionality of the photovoltaic moduleframe slots 442′, 454′ of the alternative embodiment of the ballast traysupport bracket 430′ will be described with reference to FIGS. 68 and69. In these figures, a photovoltaic module return flange 364′, which isconnected to the photovoltaic module side flange 365′, is shown beinginserted into a photovoltaic module frame slot 442′ of a ballast traysupport bracket 430′. More specifically, as shown in these figures, thephotovoltaic module frame slot 442′ on the upstanding portion 440′ ofthe first bracket section 432′ is bordered by a chamfered wall portion458, two generally parallel straight wall portions 462, 466, and acircular wall portion 464. At the location where the chamfered wallportion 458 meets the straight wall portion 462, a projection or tooth460 is defined. Also, a second projection or tooth 465 is defined wherethe straight wall portion 466 meets the circular wall portion 464. Inthe alternative embodiment, the photovoltaic module frame slot 454′ onthe upstanding portion 452′ of the second bracket section 444′ hasgenerally the same structural configuration as the photovoltaic moduleframe slot 442′. Advantageously, the structural configurations of thephotovoltaic module frame slots 442′, 454′ allow the slots 442′, 454′ toaccommodate a wide range of photovoltaic module return flangethicknesses without the need for a friction-based installation. In orderto achieve this objective, the photovoltaic module frame slots 442′,454′ of the alternative embodiment rely on an angular design that iswider than most return flanges at a relaxed angle and then bite into thereturn flange at the final installation angle, where the circularportion of the slot 442′ 454′ surrounded by the circular wall portion464 is configured to provide minimum hoop stress to ensure slotintegrity. FIG. 68 illustrates the installation angle where thephotovoltaic module frame slot 442′ of the upstanding bracket portion440′ is positioned at an angle with respect to the photovoltaic modulereturn flange 364′ where the opening can accept the return flange 364′.FIG. 69 illustrates the final installation angle where the teeth 460,465 on the photovoltaic module frame slot 442′ bite into thephotovoltaic module return flange 364′, thereby ensuring electrical bondand frictional contact.

In an exemplary embodiment, the ballast tray support brackets 430 areformed from metal so as to enable the ballast tray support brackets 430to be both electrically conductive and structurally rigid. Thus,advantageously, the ballast tray support brackets 430, which bridge tworows of the photovoltaic modules 310 in the array 400 (see FIG. 52), areable to provide grounding or bonding between rows in the array 400(i.e., row-to-row grounding or bonding is provided by the ballast traysupport brackets 430, which span adjacent rows of photovoltaic modules310).

As best shown in FIGS. 34, 35, and 45, the photovoltaic system or array400 also includes rear wind shields or wind deflectors 422 supported bythe support assemblies 312 at the rear side of the illustrated PV modulerows in order to reduce wind load. The illustrated wind deflectors 422are held by the first upright support members 320 of the supportassemblies 312 and are shaped to deflect wind, blowing from the north,up and over the array of PV modules 310 rather than under the PV modules310 in order to reduce wind load. Referring to the assembled view ofFIG. 35 and the exploded view of FIG. 45, it can be seen that theillustrated upper flange of the wind deflector 422 is provided with aplurality of elongated apertures or slots 424 for receiving fasteners(e.g., headless-type bolts 380 described above) which secure the upperflange (upper edge portion) of the wind deflector 422 to the supportassemblies 312. The elongated apertures or slots 424 in the upper flange(upper edge portion) of the wind deflector 422 accommodate various PVmodule or panel widths 310 and accommodate for thermal expansion andcontraction of the wind deflector 422. In addition, the elongatedapertures or slots 424 in the upper edge portion of the wind deflector422 also allow for the thermal expansion and contraction of the PVmodules 310. Advantageously, as described above, the lower flange (loweredge portion) of the wind deflector 422 is not required to contain anyapertures for its securement to the support assemblies 312 because thelower flange (lower edge portion) of the wind deflector 422 merely slipsinto the wind deflector slot 352 in the rear wall 326 of the firstupright support member 320, or alternatively, into the wind deflectorslot 350 in the front wall 322 of the first upright support member 320.While the wind deflector 422 is not required in all installations of thePV system 400, it is beneficial for reducing the wind forces exerted onthe PV modules 310 and it allows the PV system 400 to be installed inmore severe wind areas. Further, as shown in FIGS. 34, 54, and 57, thewind deflectors 422 of the array are capable of being overlapped so asto additionally accommodate for PV modules 310 with different dimensions(i.e., the overlapped portions 426 of the wind deflectors 422 in FIG. 34are able to accommodate PV modules 310 having different widths).

As best shown in FIG. 45, the wind deflectors 422 have a cross-sectionalprofile that allows the wind deflectors 422 to be nested together in astacked arrangement during shipping to lower shipping and handlingcosts. That is, because the shipping size of the wind deflectors 422 isminimized by their stacked arrangement, the shipping and handling costsassociated with transporting the wind deflectors 422 is able to belowered.

In an exemplary embodiment, the wind deflectors 422 are formed frommetal so as to enable the wind deflectors 422 to be both electricallyconductive and structurally rigid. That is, the metallic wind deflectors422 are capable of providing grounding or bonding between adjacentphotovoltaic (PV) modules 310 in a row of the array 400.

Any of the features or attributes of the above described embodiments andvariations can be used in combination with any of the other features andattributes of the above described embodiments and variations as desired.

From the foregoing disclosure it will be apparent that the mountingsystems according to the present invention provide improved means formounting PV modules to flat rooftops and the like. These attributesprovide the mounting system with important advantages over competitiveproducts on the market today. These advantages include: it isenvironmentally friendly, universal and off-the shelf design, noelectrical grounding is required, rustproof, increases power density ofthe photovoltaic array by minimizing the space between rows, and no harmto the roof membrane because it does not penetrate the roof in any way.

From the foregoing disclosure and detailed description of certainpreferred embodiments, it will be apparent that various modifications,additions and other alternative embodiments are possible withoutdeparting from the true scope and spirit of the present invention. Theembodiments discussed were chosen and described to provide the bestillustration of the principles of the present invention and itspractical application to thereby enable one of ordinary skill in the artto utilize the invention in various embodiments and with variousmodifications as are suited to the particular use contemplated. All suchmodifications and variations are within the scope of the presentinvention as determined by the appended claims when interpreted inaccordance with the benefit to which they are fairly, legally, andequitably entitled.

The invention claimed is:
 1. A support assembly for supporting one ormore photovoltaic modules on a support surface, said support assemblycomprising: a body portion, said body portion including a base portionand at least one upright support member coupled to said base portion,said at least one upright support member comprising an integrally formedballast tray slot in one side thereof for receiving an upturned edge ofa ballast tray; and at least one clamp subassembly, said at least oneclamp subassembly coupled to said at least one upright support member ofsaid body portion, said at least one clamp subassembly configured to becoupled to one or more photovoltaic modules.
 2. The support assemblyaccording to claim 1, wherein said base portion comprises at least onewire clip slot for receiving a portion of a wire clip that accommodatesone or more wires of said one or more photovoltaic modules.
 3. Thesupport assembly according to claim 1, wherein said base portioncomprises at least one weep hole for draining water from a recessedportion of said base portion.
 4. The support assembly according to claim1, wherein said base portion comprises at least one integrally formedfoot member disposed on an underside of said base portion, said at leastone integrally formed foot member configured to be disposed on saidsupport surface.
 5. The support assembly according to claim 1, whereinsaid at least one upright support member of said base portion comprisesa pair of spaced-apart upright support members coupled to said baseportion, each of said upright support members including a respectivesaid ballast tray slot integrally formed in one side thereof forreceiving a respective said upturned edge of said ballast tray.
 6. Amounting system for supporting a plurality of photovoltaic modules on asupport surface, said mounting system comprising: a plurality ofphotovoltaic modules disposed in an array, said array including aplurality of rows of photovoltaic modules; a plurality of separate andspaced-apart support assemblies supporting and orienting thephotovoltaic modules in said array on said support surface, each of saidspaced-apart support assemblies comprising: a body portion, said bodyportion including a base portion and at least one upright support membercoupled to said base portion, said at least one upright support membercomprising an integrally formed ballast tray slot in one side thereof;and at least one clamp subassembly, said at least one clamp subassemblycoupled to said at least one upright support member of said bodyportion, said at least one clamp subassembly configured to be coupled toone or more of the photovoltaic modules; and a ballast tray coupled toone or more of said support assemblies, said ballast tray configured toreceive one or more ballasts therein, said ballast tray comprising atleast one upturned edge, said at least one upturned edge of said ballasttray received within said ballast tray slot of said at least one uprightsupport member of said support assembly.
 7. The mounting systemaccording to claim 6, wherein said at least one upright support memberof at least one of said support assemblies comprises a pair ofspaced-apart upright support members coupled to said base portion, eachof said upright support members including a respective said ballast trayslot integrally formed in one side thereof; and wherein said at leastone upturned edge of said ballast tray comprises a first upturned edgeand a second upturned edge, said first upturned edge being oppositelydisposed relative to said second upturned edge, and said first andsecond upturned edges of said ballast tray being received withinrespective ones of said ballast tray slots of said pair of spaced-apartupright support members.
 8. The mounting system according to claim 6,wherein said ballast tray comprises at least one drainage hole fordraining water from said ballast tray.
 9. The mounting system accordingto claim 6, further comprising at least one ballast tray supportbracket, said at least one ballast tray support bracket supporting aportion of said ballast tray on said support surface.
 10. The mountingsystem according to claim 9, wherein said at least one ballast traysupport bracket comprises a photovoltaic module frame slot formedtherein configured to receive an end portion of a photovoltaic modulereturn flange.
 11. The mounting system according to claim 9, whereinsaid photovoltaic module frame slot of said at least one ballast traysupport bracket comprises a straight portion connected to a circularrecess, said straight portion of said photovoltaic module frame slotconfigured to accommodate an insertion of said end portion of saidphotovoltaic module return flange into said photovoltaic module frameslot, and said circular recess of said photovoltaic module frame slotconfigured to accommodate a rotation of said end portion of saidphotovoltaic module return flange within said photovoltaic module frameslot after said end portion of said photovoltaic module return flangehas been inserted into said photovoltaic module frame slot.
 12. Themounting system according to claim 11, wherein said photovoltaic moduleframe slot of said at least one ballast tray support bracket is boundedby one or more teeth that are configured to bite into said photovoltaicmodule return flange after said end portion of said photovoltaic modulereturn flange has been rotated into place, thereby ensuring anelectrical bond and frictional contact between said photovoltaic modulereturn flange and said at least one ballast tray support bracket. 13.The mounting system according to claim 11, wherein said photovoltaicmodule frame slot of said at least one ballast tray support bracket isbounded by at least one angled wall portion so as to accommodate saidrotation of said end portion of said photovoltaic module return flangewithin said photovoltaic module frame slot.
 14. The mounting systemaccording to claim 9, wherein said at least one ballast tray supportbracket is configured to bridge two of said plurality of rows of saidphotovoltaic modules, and said at least one ballast tray support bracketis configured to provide grounding between said two of said plurality ofrows of said photovoltaic modules and grounding of said ballast tray tosaid array.